Bus bypass overcurrent protection

ABSTRACT

Devices and methods are described for connecting an alternative energy source (for example, solar, wind, or gas generator power) to power source lines of a utility company to back-feed power to the utility company at a circuit breaker panel. In some implementations, an over current protection device (OCPD) is electrically coupled to the source lines before the source lines are coupled to the main circuit breaker such that it can pass current from the alternative energy source to the source lines without using the busbars of the circuit breaker panel. In some implementations, the OCPD includes slots that are configured to receive the source lines when the OCPD is pushed down over the source lines. The OCPD also includes coupling structures that fit around at least a portion of the source lines, and includes one or more spike taps to electrically couple to the source lines.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 62/124,773, filed Jan. 2, 2015, which is hereby expressly incorporated by reference herein.

FIELD

This disclosure relates to devices for connecting alternative energy sources to source lines of a utility company. More specifically, this disclosure relates to devices that electrically couple to source lines in a circuit breaker panel to transfer power to the source lines without using busbars of the circuit breaker panel.

BACKGROUND

If a homeowner decides to invest in an alternative energy system (for example, rooftop-installed solar panels) with the goal of back-feeding energy to a utility, one must choose between one of two currently available options/approaches: a line-side (or supply-side, or utility-side) tap or a meter bypass. The conventional line-side tap approach is certainly the most expensive and time-consuming of these two options, but the meter bypass approach also suffers considerably by comparison with the instant invention.

For conventional line-side tapping, the homeowner must have an employee of the utility company come to their house and literally cut the power lines (120 VAC A- and B-phases and the neutral line) feeding the service panel prior to the utility meter for the home. The meter is then pulled out and connections, for example using connectors such as a KUP-L-TAP®, are made to the two 120 VAC lines below/behind the meter.

Once both of the 120 VAC lines have been tapped, each tap must be thoroughly wrapped in electrical tape resulting in large tape-wrapped taps. Power from the utility to the meter cannot be restored until an inspector from Underwriters Laboratory (UL) visits the site, inspects the taps, and deems them as having been properly installed in compliance with UL standards. (This is mandated because the main panel was not originally designed or tested to operate with lines that have KUP-L-TAP®-type connections. It may cost upwards of $3,300 to have a UL representative perform this inspection and, assuming all is in order, approve the taps. At this point, the homeowner has a document from UL certifying that the taps are UL compliant. This document must then be provided to the local utility company having jurisdiction, and the homeowner calls an employee of the utility to come back to the home, reconnect the lines, and reinsert the utility meter. The homeowner is typically without power for an entire day. Accordingly, a conventional line-side tap approach entails a considerable amount of time, effort, and expense.

The only other option currently available to homeowners interested in back-feeding alternative energy to the grid has been to bypass the utility meter. One device to bypass the meter is shown in U.S. Pat. No. 8,784,130, which describes an electrician pulling the utility meter, coupling a base meter adapter to the service panel, and then re-inserting the original utility meter into the meter adapter. Disadvantages of this approach are the cost of the components and labor needed for this installation, that the meter must be pulled, and the need to have additional components mounted on a wall. In addition, the resulting base meter adapter and utility meter combination present a rather considerable profile/lever arm that might prove alluring to playful children, who as a result may be tempted to place their hands and arms around the combination and dangle therefrom, resulting in the combination being pulled out and exposing them to full line voltage present in the jaws behind the meter.

SUMMARY

The systems, methods and devices of this disclosure each have several innovative aspects, no single one of which is solely responsible for the desirable attributes disclosed herein.

Some innovations relate to a back feed device, also referred to herein as an over current protection device (“OCPD”) for electrically coupling at least one power source line (for example, coupling two source lines each providing 120VAC phase power) in a circuit breaker panel to an alternative power source at a location before the source lines connect to a main circuit breaker in the circuit breaker panel. The source lines connected to a main circuit breaker in the circuit breaker panel and each providing power to the circuit breaker panel, to provide an electrical connection between the alternative power source and the power source lines that does not use busbars of the circuit breaker panel for the electrical connection. In some implementations the device includes means for electrically coupling including a first means for electrically coupling to a first source line configured to carry 120VAC phase A and a second means for electrically coupling to a second source line configured to carry 120VAC phase B power with two electrically distinct connections, the means for electrically coupling configured to be placed at least partially around the first and second source lines without cutting or disconnecting the first and second source lines, the means for electrically coupling configured to couple to the first and second source line at a location adjacent to the main circuit breaker in a circuit breaker panel and before the first and second source lines connect to the main circuit breaker, terminals for connecting to an alternative power source, the terminals including at least a first terminal and a second terminal, and means for protecting for an over-current condition electrically connected between the terminals and the means for electrically coupling.

Such a device may include additional aspects (e.g., features) in various embodiments. In some embodiments, the means for electrically coupling includes a threaded slot connector having a slot that allows one of the source lines to pass through the slot and be disposed within the interior of the threaded slot connector, the threaded slot connector having external threads and having at least one tapping spike disposed in the interior of the threaded slot collector, and a slotted nut having a slot that allows one of the source lines to pass through the slot and be disposed within the interior to the slotted nut, the slotted nut fitting onto the exterior threads of the threaded slot connector, the slotted nut and the threaded clot connector collectively configured to move the at last one tapping spike to electrically couple to a source line within the threaded slot connector when the slotted nut is wound onto the threaded slot connector. In some embodiments, the threaded slot connector comprises a tapered shape that deforms when the slotted nut is wound onto the exterior threads to push the at least one tapping spike into the source line. In some embodiments, the means for protecting for an over-current condition comprises at least one fuse. In some embodiments, the means for protecting for an over-current condition comprises at least one circuit breaker that is not directly electrically connected to a busbar of the circuit breaker panel.

In some embodiments, the means for coupling include two sets of one or more tapping spikes, each set of the one or more tapping spikes for electrically connecting to one of the first and second source lines. In some embodiments, the means for electrically coupling comprises two sets of one or more tapping spikes, each set of the one or more tapping spikes arranged to at least partially surround one of the source lines when the means for coupling is placed on the source lines, configured to deform to move the one or more tapping spikes to be electrically coupled to the at least partially surrounded source line when the means for coupling is crimped around the source lines. In some embodiments, the means for protecting for an over-current condition comprises at least one fuse or at least one circuit breaker. In some embodiments, the means for electrically coupling comprises a source line receptacle configured to at least partially surround a source line passing through the means for electrically coupling, the source line receptacle including at least one tapping spike, a clamping structure disposed along a lower portion of the source line receptacle to secure a source line in the source line receptacle; and at least one connector coupled to the clamping structure and disposed to be actuated from an upper surface of the device, the connector extending from the upper surface of the device to the clamping structure, the connector and clamping structure collectively configured to move the clamping structure to a closed position to secure a source line into the source line receptacle and electrically coupling the at least one tapping spike to the source line when the clamping structure is moved to the closed position.

In some embodiments, the first means for electrically coupling includes a first source line receptacle configured to at least partially surround the first source line when the device is disposed over the first source line so that the first source line passes through the means for electrically coupling, the first source line receptacle including at least one tapping spike, a first clamping structure disposed along a lower portion of the first source line receptacle to secure a source line in the first source line receptacle; at least one first connector coupled to the first clamping structure and disposed to be actuated from an upper surface of the device, the at least one first connector extending from the upper surface of the device to the first clamping structure, the at least one first connector and the first clamping structure collectively configured to move the first clamping structure to a closed position to secure the first source line into the first source line receptacle electrically coupling the at least one tapping spike to the first source line when the first clamping structure is moved to the closed position. In some embodiments, the second means for electrically coupling includes a second source line receptacle configured to at least partially surround the second source line when the device is disposed over the second source line so that the second source line passes through the means for electrically coupling, the second source line receptacle including at least one tapping spike, a second clamping structure disposed along a lower portion of the second source line receptacle to secure a source line in the second source line receptacle, and at least one second connector coupled to the second clamping structure and disposed to be actuated from an upper surface of the device, the at least one second connector extending from the upper surface of the device to the second clamping structure, the at least one second connector and the second clamping structure collectively configured to move the second clamping structure to a closed position to secure the second source line into the second source line receptacle electrically coupling the at least one tapping spike to the second source line when the second clamping structure is moved to the closed position. In some embodiments, the means for protecting for an over-current condition comprises at least one fuse or at least one circuit breaker. In some embodiments, the device further includes a power transfer bar electrically coupled to the means for electrically coupling and extending generally perpendicular to the first and second source lines to fit adjacent to one of more circuit breakers disposed beside the main circuit breaker, the power transfer bar including a first conductive bus electrically coupled to the first means for electrically coupling and to the first terminal, and a second conductive bus coupled to the second means for electrically coupling and the second terminal.

Another innovation includes a device for electrically coupling a first source line carrying 120VAC phase A power and a second source line carrying 120VAC phase B power to an alternative power source to feed power from the alternative power source to the first and second source lines without using busbars of a circuit breaker panel, the first and second source lines providing power to a main circuit breaker in a circuit breaker panel, the device including a source line coupler configured to couple to the first source line and the second source line in a circuit breaker panel at least partially around the first and second source lines without cutting or disconnecting the first and second source lines, the source line coupler including an entry portion and an exit portion having openings for the two source lines to pass thru the source line coupler when the device is placed on the first and second source line such that the exit portion is proximate to the main circuit breaker and the entry portion is distal to the main circuit breaker, the source line coupler including a first source line receptacle for receiving the first source line when the device is placed over the first source line such that the first source line is disposed in the first line receptacle, the first source line receptacle including at least one first conductive tapping spike disposed to contact the first source line when the first source line is secured in the first source line receptacle, a second source line receptacle for receiving the second source line when the device is placed over the second source line such that second source line is disposed in the second line receptacle, the second source line receptacle including at least one second conductive tapping spike disposed to contact the second source line when the second source line is secured in the second source line receptacle, terminals for connecting to an alternative power source, the terminals including at least a first terminal and a second terminal, and a first over-current protector and a second over-current protector that stop current from flowing at a predetermined threshold level, the first over-current protector electrically connected between at least one first tapping spike and the first terminal, and the second over-current protector electrically coupled between the at least one second tapping spike and the second terminal.

Such a device may include additional aspects (e.g., features) in various embodiments. In some embodiments, the first and second over-current protectors are fuses. In some embodiments, the first and second over-current protectors are circuit breakers. In some embodiments, the device further includes a power transfer bar electrically coupled to the source line coupler and extending generally perpendicular to first and second source lines that are secured in the source line coupler, the power transfer bar configured to fit adjacent to one of more circuit breakers disposed beside the main circuit breaker, the power transfer bar including a first conductive bus electrically coupled between the at least one first tapping spike and the first terminal, and a second conductive bus electrically coupled between the at least one second tapping spike and the second terminal second means for electrically coupling and the second terminal. In some embodiments, the source line coupler includes a first clamping structure disposed along a portion of the first source line receptacle to secure the first source line in the first source line receptacle; and at least one connector coupled to the first clamping structure and disposed to be actuated from an upper surface of the device, the connector extending from the upper surface of the device to the first clamping structure, the connector and first clamping structure collectively configured to move the clamping structure to a closed position to secure the first source line into the first source line receptacle and electrically couple the at least one first tapping spike to the first source line when the first clamping structure is moved to the closed position. In some embodiments, the first clamping structure is coupled to two connectors disposed to be actuated from the upper surface of the device, the two connectors extending from the upper surface of the device to the first clamping structure and coupled to the first clamping structure. In some embodiments, the first clamping structure is configured to be adjusted using one or more of the two connectors coupled to the first clamping structure to change the size of the first source line receptacle.

Another innovation includes a method for installing a device to back feed energy from an energy source to source lines in a preexisting circuit breaker panel. In some embodiments the method includes inserting a back feed device in a circuit breaker panel between a main circuit breaker and a utility meter, the back feed device dimensioned to couple to a first source line and a second source line and be disposed within the circuit breaker panel. The back feed device includes a source line coupler configured to couple to the first source line and the second source line and at least partially around the first and second source lines, the source line coupler including a first source line receptacle for receiving the first source line such that the first source line is disposed in the first line receptacle, the first source line receptacle including at least one first conductive tapping spike disposed to contact the first source line when the first source line is secured in the first source line receptacle, a second source line receptacle for receiving the second source line, the second source line receptacle including at least one second conductive tapping spike disposed to contact the second source line when the second source line is secured in the second source line receptacle. The back feed device further includes terminals for connecting to an alternative power source, the terminals including at least a first terminal and a second terminal, and a first over-current protector and a second over-current protector that stop current from flowing at a predetermined threshold level, the first over-current protector electrically connected between the at least one first tapping spike and the first terminal, and the second over-current protector electrically coupled between the at least one second tapping spike and the second terminal. The method may also include coupling the source line coupler to the first source line and the second source line.

Another innovation includes a circuit breaker including a first connector configured to connect to a first busbar supplying power to the breaker in a first phase, a second connector configured to connect to a second busbar supplying power to the breaker in a second phase, a first bimetallic strip in thermal connection with the first busbar, and a second bimetallic strip in thermal connection with the second busbar, the first and second bimetallic strips configured to deform and interrupt the connections between the breaker and the first and second busbars if either of the first or second bimetallic strips exceed a threshold temperature.

In some embodiments, the first bimetallic strip can form a part of the electrical connection between the first busbar and the breaker. In some embodiments, the second bimetallic strip can form a part of the electrical connection between the second busbar and the breaker. In some embodiments, the circuit can additionally include a linking member configured to engage or retain a portion of the first bimetallic strip and a portion of the second bimetallic strip, where displacement of the first bimetallic strip displaces the linking member and the second bimetallic strip. In some embodiments, the linking member can include a first notch configured to retain a portion of the first bimetallic strip and a second notch configured to retain a portion of the second bimetallic strip, where the width of the first and second notches is less than the travel ranges of the first and second bimetallic strips. In some embodiments, the circuit breaker can additionally include a reset member configured to displace the linking member to move the first and second bimetallic strips to a reset position.

Another innovation includes a power transfer structure, including a first section configured to retain a portion of a first power line, a second section configured to retain a portion of a second power line and place the second power line in electrical communication with the first power line, and a bimetallic strip in thermal contact with at least one of the first or second power lines and configured to deform and interrupt the electrical communication between the first power line and the second power line if the temperature of the bimetallic strip exceeds a threshold temperature.

In some embodiments, the bimetallic strip can form part of an electrical connection between the first power line and the second power line. In some embodiments, the first section can be configured to expose and contact a conductive portion of the first power line and wherein the second section is configured to expose and contact a conductive portion of the second power line. In some embodiments, the first section can include an electrical lug and a clamping screw. In some embodiments, the first section can include a tapping spike. In some embodiments, the second section can include an electrical lug and a clamping screw. In some embodiments, the second section can include a tapping spike. In some embodiments, the bimetallic strip can be linked to a second bimetallic strip in another power transfer structure configured to form an electrical connection between a third power line and a fourth power line, where deformation of the bimetallic strip induces deformation of the second bimetallic strip.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain inventive aspects will hereinafter be described in conjunction with the appended drawings, provided to illustrate and not to limit the disclosed aspects. In these figures, reference numerals are generally used to indicate the same component, however, various configurations of an indicated component may all be referred to using the same reference numeral for clarity of the description. In some figures, components that are indicated by a reference numeral, and that also are illustrated in other figures, may not be described each time for clarity of the disclosure, and in such cases other description of such commonly referenced components in other implementations may apply, unless indicated otherwise, explicitly or by context.

FIG. 1 illustrates an example of a circuit breaker panel connected to an electrical meter.

FIG. 2 illustrates an example of a circuit breaker panel connected to an electrical meter, and a connection from an alternative energy source (e.g., solar power, wind power, water power, generator) also connected to the circuit breaker panel, the connection of the alternative energy source to the busbars being at a location proximate to where the main circuit breaker is coupled to the busbars (e.g., beside the main circuit breaker).

FIG. 3 illustrates an example of a circuit breaker panel connected to an electrical meter, and a connection from an alternative energy source (e.g., solar power, wind power, water power, generator) also connected to the circuit breaker panel, the connection of the alternative energy source to the busbars being at a location distal to the main circuit breaker (e.g., at the opposite side of the busbars from the main circuit breaker).

FIG. 4 illustrates an example of an over current protection device (OCPD) connected to power source lines that provides power into a circuit breaker panel bypassing the busbars, according to some embodiments, and which certain aspects are further illustrated in FIG. 8.

FIG. 5 illustrates another example of an OCPD connected to power input lines that provides power into a circuit breaker panel bypassing the busbars, and which certain aspects are further illustrated in FIG. 9.

FIG. 6 illustrates another example of an OCPD connected to power input lines that provides power into a circuit breaker panel bypassing the busbars, according to some embodiments, and which certain aspects are further illustrated in FIG. 10.

FIG. 7 illustrates another example of an OCPD connected to power input lines that provides power into a circuit breaker panel bypassing the busbars, according to some embodiments, and which certain aspects are further illustrated in FIG. 11.

FIG. 8A illustrates an example of a top view of the OCPD illustrated in FIG. 4.

FIG. 8B illustrates a front view of the OCPD illustrated in FIG. 8A.

FIG. 8C illustrates an example of a side view of the OCPD illustrated in FIG. 8A, before the OCPD is coupled to power lines (which may also be referred to as “before tap” indicating that the OCPD is not electrically coupled to or tapped into the power lines such that electrical current can flow from the power lines to the OCPD), for example, power lines that provide power into a circuit breaker panel.

FIG. 8D illustrates an example of a side view of the OCPD illustrated in FIG. 8C after the OCPD is coupled to the power lines (which may also be referred to as “after tap” indicating that the OCPD is electrically coupled to or tapped into the power lines such that electrical current can flow from the power lines to the OCPD), for example, power lines that provide power into a circuit breaker panel.

FIG. 9A is a top view of an example of an OCPD that can be, for example, the OCPD illustrated in FIG. 5.

FIG. 9B is a front view of an example of the OCPD that is illustrated in FIG. 9A.

FIG. 9C is a side view of an example of the OCPD that is illustrated in FIG. 9A.

FIG. 9D illustrates a crimping tool that may be used to couple the OCPD to the source lines.

FIG. 10A illustrates a top view of the OCPD illustrated in FIG. 6, the OCPD including one or more pivoting arm structures that push tapping spikes into power wires.

FIG. 10B illustrates a front view of the OCPD illustrated in FIG. 10A.

FIG. 10C illustrates an example of a side view of the OCPD illustrated in FIG. 10A.

FIGS. 11-16 illustrate an example of an embodiment of a process of installing an OCPD showing various stages of coupling the OCPD to source power cables and inserting fuses into the OCPD.

FIG. 11 illustrates a front view of an example of an OCPD illustrated in FIG. 7, showing a configuration that has tapping spikes in place around power source cables but the tapping spikes are not tapped into the power cables and fuses are not inserted into the OCPD.

FIG. 12 illustrates another front view of an example of the OCPD illustrated in FIG. 11, showing a configuration of the OCPD having tapping spikes around power source cables and tapped into the power cables, and fuses are not inserted into the OCPD.

FIG. 13 illustrates another front view of an example of the OCPD illustrated in FIG. 11, showing a configuration of the OCPD having tapping spikes around power source cables and tapped into the power cables, and also illustrating fuses positioned to be inserted into the OCPD.

FIG. 14 illustrates another front view of an example of the OCPD illustrated in FIG. 11, showing a configuration of the OCPD having tapping spikes around power source cables and tapped into the power cables, and also illustrating fuses positioned as being inserted into the OCPD.

FIG. 15 illustrates another front view of an example of the OCPD illustrated in FIG. 11, showing a configuration of the OCPD having tapping spikes around power source cables and tapped into the power cables, and also illustrating fuses positioned as being inserted into the OCPD but not tightened.

FIG. 16 illustrates another front view of an example of the OCPD illustrated in FIG. 11, showing a configuration of the OCPD having tapping spikes around power source cables and tapped into the power cables, and also illustrating fuses positioned as inserted into the OCPD and tightened.

FIG. 17 illustrates an example of an OCPD connected to power input lines that provide power into a circuit breaker panel, and which certain aspects are further illustrated in FIG. 18. This is a live-load wiretap fuse block embodiment with four-bolt clamp-style taps and with a twin alternative energy breaker connected in front of the main breaker. Note: a twin breaker only uses a single breaker space (typically 1″ in width) for a 2-pole breaker.

FIG. 18 illustrates details of the OCPD of FIG. 17.

FIG. 19 illustrates an example of an OCPD connected to power input lines that provide power into a circuit breaker panel, and which certain aspects of various embodiments are further illustrated in FIGS. 18 and 20. This is a live-load wiretap embodiment with single-bolt clamp-style tapping collar. In this embodiment circuit breakers are used as a current protector device instead of fuses. Some jurisdictions require breakers even though sensitive equipment would be better protected with fuses as the OCPDs.

FIG. 20 illustrates an example of an implementation of an OCPD that includes a twin two-pole circuit breaker, dimensioned to use the space of a “normal sized” breaker space for a two-pole circuit breaker, and disposed adjacent to the main circuit breaker to connect to the source lines inside the circuit breaker panel and prior to connecting to the main circuit breaker.

FIG. 21 illustrates an example of an implementation of an OCPD that includes a twin two-pole circuit breaker that is dimensioned to use the space of a “normal sized” breaker space for a two-pole circuit breaker coupled and a push-on configured electrical coupling device, aspects of which are illustrated in FIGS. 30A-30D. this embodiment is a live-load tapered-thread nut tap embodiment with 2-pole twin alternative energy breakers disposed in front of and connected to the main breaker (“in front of” as used herein referring to a connection location to the source lines before the source lines connect to the main circuit breaker, typically after the source lines enter the circuit breaker panel).

FIG. 22 illustrates an example of an implementation of an OCPD that includes a twin two-pole circuit breaker that is dimensioned to use the space of a “normal sized” breaker space for a two-pole circuit breaker coupled and a crimp-on configured electrical coupling device, aspects of which are illustrated in FIGS. 31A-31D. This embodiment is a live-load crimp-style tap embodiment with 2-pole twin alternative energy breakers disposed in front of and connected to the main breaker.

FIG. 23 illustrates an example of an implementation of an OCPD that includes terminals for receiving power input from alternative energy sources on an another circuit breaker which may be disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 32A-32D. This implementation is a live-load tapered-thread nut tap embodiment with a standard dual 2-pole alternative energy breaker disposed to the side of and connected to the main breaker.

FIG. 24 illustrates an example of an implementation of an OCPD that includes terminals for receiving power input from alternative energy sources on an another circuit breaker which may be disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 33A-33D. A power transfer bar 24 is used because the twin breaker is not connected to the busbar. Twin breakers may be used when there is limited space within the breaker/service panel. Some breaker boxes have ample room, in which case one wouldn't need to use a narrower twin breaker, which costs more (the narrower the breaker, the more it costs).

FIG. 25 illustrates an example of an implementation of an OCPD that includes terminals for receiving power input from alternative energy sources on an another circuit breaker which, in some implementations, is disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 34A-34D. This is a live-load crimp-style tap embodiment with a fuse block and a standard double alternative energy breaker OCPD.

FIG. 26 illustrates an example of an implementation of an OCPD that includes terminals for receiving power input from alternative energy sources on an another circuit breaker (a twin alternative energy breaker OCPD), which is disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 35A-35D.

FIG. 27 illustrates an example of an implementation of an OCPD that includes terminals for receiving power input from alternative energy sources on an another circuit breaker which, in some implementations, is disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 36A-36D. This is a live-load tapered-thread nut tap with fuse block and twin alternative energy breaker (OCPD).

FIG. 28 illustrates an example of an implementation of an OCPD that includes terminals for receiving power input from alternative energy sources on an another circuit breaker (for example, a standard double alternative energy breaker OCPD), which is disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 37A-37D.

FIG. 29A illustrates an example of an implementation of an OCPD that includes terminals for receiving power input from alternative energy sources on a standard two-pole circuit breaker which, in some implementations, is disposed beside the main circuit breaker, aspects of which are further illustrated in FIG. 39. This implementation is a live-load crimp-style tap embodiment with a standard double alternative energy breaker OCPD.

FIG. 29B illustrates an example of an implementation of an OCPD that includes terminals for receiving power input from alternative energy sources on a twin two-pole circuit breaker which, in some implementations, is disposed beside the main circuit breaker, aspects of which are further illustrated in FIG. 39. This embodiment is a live-load crimp-style tap embodiment with new twin (duplex, tandem) alternative energy breaker (OCPD) that is still 2″ across but that supports four circuits (instead of two as with a standard double breaker).

FIGS. 30A-30D illustrate additional aspects of the OCPD of FIG. 21.

FIGS. 31A-31D illustrate additional aspects of the OCPD of FIG. 22.

FIGS. 32A-32D illustrate additional aspects of the OCPD of FIG. 23.

FIGS. 33A-33D illustrate additional aspects of the OCPD of FIG. 24.

FIGS. 34A-34D illustrate additional aspects of the OCPD of FIG. 25.

FIGS. 35A-35D illustrate additional aspects of the OCPD of FIG. 26.

FIGS. 36A-36D illustrate additional aspects of the OCPD of FIG. 27.

FIGS. 37A-37D illustrate additional aspects of the OCPD of FIG. 28.

FIG. 38 further illustrates aspects of an embodiment of an OCPD using a threaded slot connector and a slotted nut, for example, as illustrated in FIGS. 8, 21, 23, 24, 27, 28, 30, 33 and other similar embodiments.

FIGS. 39A-39D examples of embodiments that use a crimping coupler to electrically couple an OCPD to source lines. This can be done while the source lines are live, obviating the need to remove the utility meter.

FIG. 40 is a schematic illustration of a main service panel with an installed bypass breaker in electrical communication with power transfer posts on the source lines before the main breaker.

FIG. 41A is a detail cross-sectional view of the power transfer post within region A of FIG. 40, along a plane orthogonal to a source line at the power transfer post.

FIG. 41B is a detail cross-sectional view of the region A of FIG. 40, along a plane orthogonal to the plane of FIG. 41A at the power transfer post, illustrating the use of a bimetallic strip.

FIG. 42 is a cross-sectional view of a power transfer post such as the power transfer post of FIG. 41B, with a bimetallic strip shown in an untripped position.

FIG. 43 schematically illustrates connections to alternating busbars in a series of breakers in a main service panel.

FIG. 44A schematically illustrates a connection between a busbar and a bypass breaker which utilizes a bimetallic strip.

FIG. 44B is a detail cross-sectional view of region C of FIG. 44A, illustrating the bimetallic strip connection to the circuit breaker.

FIG. 45A is a side cross-sectional view of another embodiment of a bypass breaker with two bimetallic strips arranged in series, shown in a tripped position.

FIG. 45B is a side cross-sectional view of the bypass breaker of FIG. 45B, with the bimetallic strips shown in a reset position.

FIG. 46 is a cross-sectional view of an alternative energy breaker which utilizes a bimetallic strip safety feature.

FIG. 47 illustrates a method of inserting a back feed device into a circuit breaker panel where the source lines need not be disconnected and power need not be de-energized for the installation to take place.

DETAILED DESCRIPTION OF CERTAIN INVENTIVE ASPECTS

Embodiments of the disclosure relate to systems and techniques for implementing devices and methods that can be used to electrically couple alternative energy sources to existing circuit breaker panels for residential and commercial implementations. The so-called “120% Rule” is a limiting factor, for solar designers and installers, in designing and installing a system to maximize solar production from residential homes as well as commercial structures, in that it limits the maximum power output threshold possible from a given solar system, without having to resort to other methodologies that are expensive and time intensive.

For many houses and businesses, the power source lines coming in to a house from an electric utility company are two phases of 120VAC (namely, phases “A” and “B”) and a neutral. These lines go through the utility meter, which, if one does not have an alternative energy source (e.g., solar panels) only spins forward, and one is charged based on the number of kilowatt hours (kWh) one consumes. After the wires go through the meter, they are routed to your 100 A or 200 A main service disconnect (aka main breaker). Note that some residences have 125 A, 400 A, etc., depending on the size and energy requirements of the home. For example, for a single family home (without a suite) having a gas furnace, a gas stove, and perhaps a gas water heater, 100 A typically is sufficient. On the other hand, if one is looking at a home that has a suite and, say, two electric washers and dryers, electric furnaces, electric stove(s), and one or more electric vehicles, a sauna, etc., or a dwelling in a remote location that does not have natural gas service, then a 100 A panel will likely be strapped and need to be upgraded to 200 A.

The busbar rating in a residential service panel typically matches the rating/size of the main breaker. For example, a service equipped with a 100 A main breaker allows 100 A of current to be provided to the busbar—that is, the main breaker will trip if more than 100 A is presented to the busbar. By NEC code (the “120% Rule”), a breaker connected to an alternative energy system must be installed at the opposite end (usually the bottom) of the busbar from the end (typically the top) at which the main breaker is installed.

The available above-described available approaches for connecting alternative energy systems to main service panels include many issues. For example, the comparative high cost (w/r/t conventional line-side tapping) scheduling issues (i.e., arranging when various individuals from different entities can meet at the home/install site), indefiniteness of work schedules (as inspectors routinely quote three-hour windows during which they may show up), time that a given electrician has to be on site, etc. The OCPDs described herein eliminate many, if not all, of such issues, perhaps most notable being because the busbar is bypassed, the 120% rule does not have to be observed, thereby allowing the installation of arbitrarily large alternative energy systems.

The various embodiments disclosed in the instant application can be implemented without turning off power to the main panel. That is, each embodiment is installed by the live tapping of both phases (A and B) of incoming 120VAC line power (and, of course, three-phases in commercial applications). The OCPD devices, may simply be connected manually (in some cases without tools) to the power coming into the main breaker (for either two- or three-phase applications), literally pushed down over the conductors and either threadably engaged, crimped on, or clamped tightened to establish electrical contact with the main power.

FIG. 1 illustrates an example of a typical 200 amp circuit breaker panel 2 connected to an electrical meter 1. In the implementation described in FIG. 1, the circuit breaker panel 2 includes a first busbar 5 a for phase A 120VAC power and a second busbar 5 a for phase B 120VAC power. In this example, each of the busbars 5 a and 5 b are 100 amp busbars. Source line 4 a is electrically coupled, to the electric meter 1 and, via the main circuit breaker 3, to a busbar of the circuit breaker panel, for example busbar 5 a, and provides phase A 120VAC power. Source line 4 b is electrically coupled to the electric meter 1 and, via the main circuit breaker 3, to a busbar of the circuit breaker panel, for example busbar 5 b, and provides phase B 120VAC power. The circuit breaker panel 2, in this example, also includes a plurality of two-pole 240VAC circuit breakers 40 (or “breakers”), each electrically coupled to busbars 5 a and 5 b. Neutral line 4 c is electrically coupled to the electric meter and neutral busbar 32 of the circuit breaker panel 2. The circuit breaker panel also may include a grounding bar 31. Indicator 41 illustrates that from this point down (as references to the orientation of the figure), the maximum load on the busbars 5 a and 5 b is the breaker amperage. For example, if 125 amps were run through one of the busbars 5 a, 5 b the busbar would overheat and likely catch fire. Circuit breaker panels may also include one or more single pole circuit 120VAC breakers.

FIG. 2 illustrates an example of the circuit breaker panel 2 connected to an electrical meter 1, and also connections 61 a and 61 b from an alternative energy source (e.g., solar power, wind power, water power, or generator) connected to the circuit breaker panel 2 via a twin two-pole circuit breaker 39. As illustrated in FIG. 2, the circuit breaker 39 is located beside the main circuit breaker 3, a location proximate to where the main circuit breaker 3 is coupled to the busbars 5 a, 5 b (e.g., beside the main circuit breaker 3). Such placement of the alternative energy breaker would constitute a non-code-compliant installation as per the guidelines set out by the National Electrical Code (NEC), specifically NEC 690.64, which mandates that the main breaker 3 and alternative energy (e.g., solar) breaker 39 be connected at opposite ends of the busbars 5 a, 5 b. The rationale for this is that such placement prevents any localized overheating of the busbars 5 a, 5 b that otherwise may occur when large amperages are presented to a busbar 5 a, 5 b, for example, the amperage from the solar breaker 39 that is back-fed through a busbar 5 a, 5 b to a utility or battery backup, etc.).

FIG. 3 illustrates an example of a circuit breaker panel 2 connected to an electrical meter 3. Electrical connections 61 a and 61 b from an alternative energy source (e.g., solar power, wind power, water power, generator) also connected to the circuit breaker panel 2. In this implementation, the connections 61 a and 61 b of the alternative energy source to the busbars 5 a and 5 b being at a location distal to the main circuit breaker 3, e.g., at the opposite side of the busbars 5 a and 5 b from the main circuit breaker 3.

The electrical configuration illustrated in FIG. 3 is an example of a properly installed solar breaker 39. This would be a National Electrical Code (NEC) 690 120 rule compliant installation. The NEC was established to keep electrical installations uniform and standard, to keep electrical installations safe. The explanation for the NEC 690 120 rule, indicates that you take the busbar amperage rating times 120%, minus the breaker amperage, and the difference between the two is the total amount that you can back feed through the busbars, provided that you put the alternative energy breaker on the opposite end of the panel where the main breaker is located. For a busbar with a 100 amp rating, the formula is

busbar rating (100 A)×120%−minus the main breaker rating (100 A)=20 A

This means you're able to back-feed 20 A from an alternative electrical source, provided that the alternative energy breaker 39 is on the opposite end of the busbar. Accordingly, as illustrated in FIG. 3, if the main breaker 3 is located on the top of the busbars 5 a, 5 b (for example, in reference to the FIG. 3 orientation) then your alternative energy breaker 39 would be located on the bottom of the busbars 5 a, 5 b, that is, the opposite end of the busbars 5 a, 5 b from the main breaker 3. This arrangement would allow the energy to be absorbed through the middle of the busbars 5 a, 5 b. Many of the components and structure of over current protection devices disclosed herein are the same as in the various illustrated implementations. Accordingly, not every component of each implementation is described in every instance for efficiency of disclosure, and description relating to a component in one figure may be considered as description of an identical or similar component in another figure, as one of skill in the art will appreciate.

FIG. 4 illustrates an example of an implementation of an over current protection device (“OCPD”) 11 that provides electrical connections from an alternative power source to the source lines 4 a, 4 b without providing current through the busbars 5 a, 5 b. The OCPD 11 is disposed in the circuit breaker panel 2 and electrically coupled to the source lines 4 a, 4 b prior to where the source lines 4 a, 4 b are coupled to the main circuit breaker 3. As illustrated in many of the implementations herein, the OCPD is disposed adjacent to the main circuit breaker 3 and is electrically coupled to the source lines 4 a, 4 b inside the circuit breaker panel 2 at a location after the source lines 4 a, 4 b have entered the circuit breaker panel 2 and prior to the source lines 4 a, 4 b connecting to the main circuit breaker 3. Any component(s) of the OCPD 11 that is used to couple the OCPD 11 to the source lines 4 a, 4 b may be referred to generally as a “source line coupler” in this disclosure. The main circuit breaker 3 (or “main breaker 3”) includes two breaker switches 125, one for phase A 120VAC power and one for phase B 120VAC power, and a bar 126 that connects the switches 125 to disconnect both the A and B phase power if either one of them is subject to an electrical condition that causes one of the switches 125 trip, disconnecting both phase A and B power.

In various configurations of OCPD's 11 described herein, the source lines pass physically through a portion of the OCPD 11, for example, the source line 4 a, 4 b pass through and/or past, partially or wholly, electrical coupling means (or structure) of the OCPD 11 that electrically couple the OCPD to the source lines 4 a, 4 b. That is, the OCPD 11 is connected to the source lines 4 a, 4 b and to an alternative power source (not shown in this illustration). Other configurations of OCPD's 11 are described herein, each having certain aspects that may be advantageous to use in certain installations and implementations. One advantage of implementations of the OCPD 11 is that it can be safely installed without disconnecting power in the source lines 4 a, 4 b, for example, without pulling the utility meter 3 to disconnect power to the source lines 4 a, 4 b. Another advantage of implementations of the OCPD 11 is that the source lines 4 a, 4 b do not have to be severed or disconnected from the main circuit breaker 3. Another advantage of implementations of the OCPD 11 is that it is configured to entirely with dimensions to fit into a circuit breaker panel 3 (for example, as illustrated). Implementations of the OCPD 11 where it is housed completely within the circuit breaker panel 3 outer walls and door provide security and electrical safety, and it also provides an aesthetically pleasing installation that does not need additional boxes and connections that are outside of the circuit breaker panel 2. Other configurations of systems that tap into source lines 4 a, 4 b that require installation of one or more additional electrical boxes outside of the circuit breaker panel 2, and electrical lines connecting the additional electrical boxes to the source lines may be more costly due the need for more components and may require labor intensive processes to properly connect them, increasing installation costs.

In various implementations described herein, the OCPD 11 may include one or more fuses, one or more breakers, or both, to ensure the electrical safety of the alternative power source connection and to meet any relevant electrical standards/codes. A s used herein, the term “over-current protector” may generally refer to either a fuse or a circuit breaker. OCPD 11 is configured to be installed without turning off the power in source lines 4 a, 4 b. In the particular implementation illustrated in FIG. 4, the OCPD 11 includes two fuses 22, one for each of the phase A and B 120VAC power. The OCPD 11 is mechanically structured to fit over the source lines 4 a, 4 b such that it can be pushed onto the source lines 4 a, 4 b. That is, from the orientation of FIG. 4, the OCPD 11 can be pushed (into the page) over the source lines 4 a, 4 b such that the source lines 4 a, 4 b do not need to be severed or removed from the main circuit breaker 3 to be electrically connected to (or tapped into). The OCPD 11, in this example, is connected to each of the source lines 4 a, 4 b using tapered thread nut taps 14, one for each of the source lines 4 a, 4 b, each nut tap 14 having a slot that fits over one of the source lines 4 a, 4 b. The OCPD 11 is dimensioned to fit into a circuit breaker panel 2. Additional aspects of the OCPD 11 are described in reference to FIGS. 8A-8D.

FIG. 5 illustrates another example of a configuration of an OCPD 11 that is connected to source lines 4 a, 4 b that may run from a utility meter 1 to a circuit breaker panel 2, and that provide power to busbars 5 a, 5 b through a main circuit breaker 3 having a surface 3 a that is exposed and visible when viewing the main circuit breaker 3 installed in the circuit breaker panel 2 as seen in FIG. 5. The OCPD 11 is configured to be installed without turning off the power in source lines 4 a, 4 b, adjacent to the main circuit breaker 3. Many of the components illustrated in FIG. 5 are the same as illustrated in FIG. 4, for example, source lines 4 a, 4 b, busbars 5 a, 5 b, neutral bar 32, utility meter 1, circuit breaker panel 2, and ground bar 31. The OCPD 11 illustrated in FIG. 5 includes two terminals 18 which provide an electrical connection point to receive power from an alternative energy source (not shown in FIG. 5). The OCPD 11 also includes two fuses 22 each configured electrically in series between one of the terminals 18 and one of the source lines 4 a, 4 b. The OCPD 11 can also be connected to the source lines by pushing the OCPD 11 down over the source lines 4 a, 4 b so the source lines 4 a, 4 b do not need to be disconnected to be electrically coupled to the OCPD 11. In the OCBD 11 configuration of FIG. 5, the connections to the source lines are made by crimping spike electrical taps into the source lines 4 a, 4 b, as further illustrated in FIGS. 9A-9D. In any of the various embodiments described herein, the illustrated OCPD 11 can be used in a three phase application. For example, an OCPD can include coupling means to couple to each of the source lines for incoming three-phase power (e.g., before a main breaker), the OCPD can include an energy source feedback terminal for connection to another system for supplying energy, and the OCPD can include an over-current protection device in line between each of the terminals and each source line. Additional aspects of the OCPD 11 are also described in reference to FIGS. 9A-9D.

FIG. 6 illustrates another example of an OCPD 11 connected to power source lines 4 a, 4 b that are connected to a circuit breaker panel 2 via a main circuit breaker 3. The configuration of the OCPD 11 illustrated in FIG. 6 includes two fuses 22 and terminals 18 for connection to an alternative energy source. This OCPD 11 is configured to be installed without turning off the power in source lines 4 a, 4 b. The fuses 22 provide a fused connection between each of the terminals 18 and one of the source lines 4 a, 4 b. The OCPD 11 also includes pivot arm taps 17 (FIG. 10) that are used to tap into the source lines 4 a, 4 b electrically coupling the OCPD 11 to the source lines 4 a, 4 b. Screws 15 have an exposed screw head that is used to tighten the pivot arms 17 onto the source lines 4 a, 4 b. This configuration is further described in reference to FIGS. 10A, 10B, and 10C.

FIG. 7 illustrates another example of an OCPD 11 connected to power source lines 4 a, 4 b that are connected to a circuit breaker panel 2 via a main circuit breaker 3. This OCPD 11 is configured to be installed without turning off the power in source lines 4 a, 4 b. The configuration of the OCPD 11 illustrated in FIG. 7 includes two fuses 22 and two terminals 18 for connection to an alternative energy source. That is, each of the fuses 22 provide a fused connection between one of the terminals 18 and one of the source lines 4 a, 4 b. The configuration of the OCPD 11 illustrated in FIG. 11 includes a single screw 15 that is used to connect the OCPD 11 to the source lines 4 a, 4 b using a single bolt clamp tap. This configuration is further described in reference to FIGS. 11A and 11B.

FIG. 8A illustrates an example of a top view of the OCPD 11 illustrated in FIG. 4. That is, the top surface 3 a of main breaker 3 is exposed/viewable when the circuit breaker panel 2 is viewed from the perspective shown in FIG. 4. The upper surface (or top surface) 63 of the OCPD 11 (and other OCPD's 11 disclosed herein) may also be exposed/visible when the circuit breaker panel 2 is viewed from the perspective shown in FIG. 4. For example, fuses 22 disposed in the upper surface 63 may be visible and accessible in the circuit breaker panel 2 for easy access/replacement. FIG. 8B illustrates a “front view” of the OCPD 11 illustrated in FIG. 8A, that is, from the viewpoint of the source lines 4 a, 4 b looking towards the OCPD 11. FIG. 8C illustrates an example of a “side view” of the OCPD 11 illustrated in FIG. 8A, before the OCPD 11 is coupled to the source lines 4 a, 4 b (which may also be referred to as “before tap” indicating that the OCPD 11 is not electrically coupled to or tapped into the power lines such that electrical current can flow from source lines 4 a, 4 b to the OCPD 11). In reference to FIG. 4, the side view is from the top of FIG. 4 looking down on the side of the OCPD 11. FIG. 8D illustrates an example of the side view of the OCPD 11 illustrated in FIG. 8C after the OCPD is coupled to the source lines 4 a, 4 b (which may also be referred to as “after tap” indicating that the OCPD 11 is electrically coupled to or tapped into the source lines 4 a, 4 b such that electrical current can flow from the source liens 4 a, 4 b to the OCPD 11). This OCPD 11 is configured, as described below, such that it can be coupled to the source lines 4 a, 4 b without turning off power to the source lines 4 a, 4 b. The OCPD 11 can be used in a three phase application.

The OCPD 11 includes two threaded slot connectors 47 and two slotted nuts 14 that are sized to wind over the threaded slot connectors 47. As shown in the example of FIG. 8B, the OCPD 11 has two openings 127 that receive the source lines 4 a, 4 b and allow the OCPD 11 to fit over, and be placed over, the source lines 4 a, 4 b such that the source lines 4 a, 4 b run through a portion of the OCPD 11 before the source lines 4 a, 4 b connect to the main breaker 3. The OCPD 11 includes source line receptacles 62 where the source lines 4 a, 4 b are seated when coupled to the OCPD 11. OCPD's 11 described herein can be characterized as having an entry portion 64 where a source line enters the OCPD 11 (e.g., a side of the OCPD 11 distal to the main circuit breaker 3) and also as having an exit portion 65 where a source line exits the OCPD 11 (e.g., a side of the OCPD 11 proximate to the main circuit breaker 3). The width w of the openings 127 are sized to accommodate the source lines 4 a, 4 b. For example, is some embodiments the width w of the openings 127 can be in the range from 5 mm in diameter (˜60 A) to about 12 mm in diameter (˜195 A). The threaded slot connectors 47 and slotted nuts 14 each include an opening (slot) 128 that allow the source lines 4 a, 4 b to be received into the threaded slot connectors 47 and the slotted nuts 14 such that the source lines 4 a, 4 b are surrounded by the threaded slot connectors 47 and the slotted nuts 14 (except where the slot is) when the OCPD 11 is placed over and pushed down onto the source lines 4 a, 4 b. For this type of coupling embodiment, as illustrated in FIGS. 8C and 8D, slotted nut 14 may include a tapered thread structure that is wider at the portion 14 a of slotted nut 14 that first contacts the threaded slot connector 47 when wound on, and narrower at the portion 14 b that later contacts the threaded slot connector 47.

The slotted thread connectors 47 have a tapered configuration (FIG. 8C) so that as the slotted nuts 14 are wound over the threaded slot connectors 47, the threaded slot connectors 47 are electrically coupled to the source lines. In such coupling connections disclosed herein, the slotted nuts 14 may be tightened by hand or the slotted nuts may be tightened using a tool, and the outside surface of the slotted nut 14 may accordingly be configured to be tightened by hand or by a tool (e.g., hexagon-shaped). In FIG. 8A the slotted nuts 14 are shown after they have been wound over the threaded slot connectors 47 and the threaded slot connectors 47 tap into a source line 4 a, 4 b, such that the slotted nuts 14 are tightened onto the threaded connectors 47, which electrically couples the OCPD 11 to the source lines 4 a, 4 b. The threaded slot connectors 47 include one or more tapping spikes 12 (FIG. 8D) that are driven into a source line 4 a, 4 b when slotted nuts 14 are tightened onto the threaded slot connectors 47.

The OCPD 11 also includes two electrical terminals 18 for connection to, and to receive power from, an alternative electrical source connected to the terminals 18. The terminals 18 are electrically coupled to the source lines 4 a, 4 b when the OCPD 11 is coupled to the source lines 4 a, 4 b via the one or more tapping spikes 12. Fuses 22 are electrically connected in serial between a source line 4 a, 4 b and a terminal 18 such that power provided to the OCPD 11 from an alternative electrical source goes through one of the fuses. In the implementation illustrated in FIG. 8, the terminals 18 are disposed on a lower portion of the OCPD 11 such that they are not visible from the front of the circuit breaker panel 2 and they are disposed within the circuit breaker panel 2. However, in other implementations the terminals 18 can be disposed on other portions of the OCPD 11, for example the top, side or the bottom of the OCPD 11.

FIG. 9A is a top view of an example of an over current protection device (OCPD) 11, for example, the OCPD 11 illustrated in FIG. 5, for example, where the surface 3 a of the main circuit breaker 3 is exposed/viewable as seen in FIG. 5. FIG. 9B is a front view of an example of the OCPD 11 that is illustrated in FIG. 9A. FIG. 9C is a side view of an example of the OCPD 11 that is illustrated in FIG. 9A. FIG. 9D illustrates one example of a crimping tool 13 that may be used to couple the OCPD 11 to the source lines 4 a, 4 b. The OCPD 11 is configured to be disposed in the circuit breaker panel 2 and electrically coupled to the source lines 4 a, 4 b before the source lines 4 a, 4 b connect to the main circuit breaker 3.

As illustrated in FIG. 9B, in this implementation, the OCPD 11 is configured be placed over the source lines 4 a, 4 b such that the source lines 4 a, 4 b pass through a portion of the OCPD 11, for example, a deformable crimping structure 12 a that includes one or more tap spikes 12. The OCPD 11 includes source line receptacles 62 where the source lines 4 a, 4 b are seated when coupled to the OCPD 11. Once the OCPD 11 is positioned on the source lines 4 a, 4 b such that the source lines 4 a, 4 b are in the crimping structure 12 a, the tap spikes 12 can be pushed into the source lines 4 a, 4 b using a crimping tool to crush the crimping structure 12 a around the source lines 4 a, 4 b, for example, the crimping tool 13 illustrated in FIG. 9D. The illustrated OCPD 11 also includes terminals 18 for connection to an alternative energy source, and that may be disposed on the top portion of the OCBD 11 as illustrated in FIG. 9A. In other implementations, the terminals 18 may be disposed on other locations of the OCPD 11. The OCPD 11 also includes two fuses 22, each one being electrically connected between one of the terminals 18 and one of the source lines 4 a, 4 b. The OCPD 11 is configured, as described below, such that it can be coupled to the source lines 4 a, 4 b without turning off power to the source lines 4 a, 4 b. The OCPD 11 can be used in a three phase application.

FIG. 10A illustrates a top view of the OCPD 11 illustrated in FIG. 6, the OCPD 11 including one or more pivoting arm structures 17 (FIG. 10B) that push tapping spikes 12 into the source lines 4 a, 4 b when the pivoting arm structures 17 are tightened using screws 15. Such pivoting arm structures 17 disclosed herein may also be referred to as “clamping structure.” FIG. 10B illustrates a front view of the OCPD 11 illustrated in FIG. 10A. FIG. 10C illustrates an example of a side view of the OCPD 11 illustrated in FIG. 10A. The OCPD 11 is configured to be disposed in the circuit breaker panel 2 and electrically coupled to the source lines 4 a, 4 b before the source lines 4 a, 4 b connect to the main circuit breaker 3. As illustrated in FIG. 9B, in this implementation, the OCPD 11 is configured be placed over the source lines 4 a, 4 b such that the source lines 4 a, 4 b pass through a portion of the OCPD 11, for example, the pivoting arm structures 17 and one or more tap spikes 12. The OCPD 11 is configured, as described below, such that it can be coupled to the source lines 4 a, 4 b without turning off power to the source lines 4 a, 4 b. Implementations of the OCPD 11 can be also used in a three phase application.

As illustrated in FIG. 10B, when the OCPD 11 is coupled to the source lines 4 a, 4 b, a portion of the OCPD 11 is disposed above the source lines 4 a, 4 b (with respect to the orientation of FIG. 10B) and the pivoting arms 17 are disposed under the source lines 4 a, 4 b. In this configuration, the pivoting arms 17 may first be placed below the source lines 4 a, 4 b, and then the OCPD 11 is placed over/around the source lines 4 a, 4 b. The OCPD 11 includes source line receptacles 62 where the source lines 4 a, 4 b are seated when coupled to the OCPD 11. In the illustrated configuration, each of the pivoting arms is coupled to two screws 15, one on either side of the pivoting arm 17, the screws 15 extending from the top portion 15 a of the OCPD 11 to the pivoting arms 17. When the screws 15 are tightened, the screws pull the pivoting arms 17 towards the source lines 4 a, 4 b driving the plurality of tapping spikes into the source lines 4 a, 4 b to couple the OCPD 11 to the source lines 4 a, 4 b. In embodiments in this disclosure that include pivoting arms 17, the OCPD 11 may also include adjustable arms 16 each coupled to a screw 15, the adjustable arm being adjustable to adjust the source line receptacle to different wire sizes and/or different breaker dimensions. The OCBD 11 further includes terminals 18 for connecting to an alternative energy source, the terminals 18 being electrically connected to the plurality of tapping spikes 12. Fuses 22 are connected between the terminals 18 and the plurality of tapping spikes 12, and are disposed at the top of the OCPD 11 (FIG. 10A) to be accessible from the circuit breaker panel 2.

FIGS. 11-16 illustrate an example of another embodiment of an OCPD 11, and illustrating showing various stages of coupling the OCPD 11 to source power cables and inserting fuses into the OCPD 11. In particular, FIG. 11 illustrates a front view of an example of an OCPD 11 that can be, for example, the OCPD 11 illustrated in FIG. 7, and that is configured to be coupled to source lines 4 a, 4 b. The OCPD 11 is configured to be disposed in a circuit breaker panel 2 and electrically coupled to the source lines 4 a, 4 b before the source lines 4 a, 4 b connect to the main circuit breaker 3. The OCPD 11 is configured, as described below, such that it can be coupled to the source lines 4 a, 4 b without turning off power to the source lines 4 a, 4 b. Implementations of the OCPD 11 can be also used in a three phase application.

The OCPD 11 illustrated in FIG. 11 includes alternative source power connection terminals 18, one or more tapping spikes 12, and apertures 220 for receiving screw-in fuse connection cases 22 (one for each source line). The OCPD 11 also includes a lower clamping structure 129 that includes tapping spikes 12 that attach to a bottom portion of a source line 4 a, 4 b and an upper coupling structure 130 having tapping spikes 12 that attach to an upper portion of a source line 4 a, 4 b. Such lower coupling structure 129 and upper coupling structure disclosed herein may also be referred to as a “clamping structure.” The OCPD 11 includes source line receptacles 62 where the source lines 4 a, 4 b are seated when coupled to the OCPD 11. In this embodiment, a screw 15 disposed in the upper 63 of the OCPD 11 is tightened, the lower coupling structure 129 and the upper coupling structure 130 are pulled together by the screw 15 and the tapping spikes 12 are driven into the source lines 4 a, 4 b. FIG. 11 illustrates an arrangement where the tapping spikes 12 are in place around power source cables 4 a, 4 b but the tapping spikes 12 are not electrically connected to the source lines 4 a, 4 b. Another two-pole 240VAC breaker 40 is illustrated as being positioned adjacent to the main breaker 3 and the OCPD 11 for context. The breaker 40 includes electrical lugs 45.

FIG. 12 illustrates another front view of the OCPD 11 illustrated in FIG. 11, showing a configuration of the OCPD 11 where the screw 15 has been tightened and tapping spikes 12 are around and tapped into the power lines 4 a, 4 b. Fuse cases 22 are not yet placed into the apertures 220 so that the terminals 18 are not yet electrically coupled to the source lines 4 a, 4 b. In this embodiment, the fuse cases 22 are screw-in fuse cases.

FIG. 13 illustrates another front view of an example of the OCPD 11 illustrated in FIG. 12, showing a configuration of the OCPD 11 similar to that of FIG. 12, except that now the screw-in fuse cases 22 are positioned over apertures 220.

FIG. 14 illustrates another front view of the OCPD 11 illustrated in FIG. 13. In this configuration, the screw-in fuse cases 22 are being inserted into the OCPD 11. Note that the insertion of the screw-in cases 22 do not couple the terminals 18 to the source lines 4 a, 4 b as this electrical coupling does not occur until fuses are placed into the screw-in fuse cases 22. As illustrated in FIG. 14, the tapping spikes 12 are around and tapped into the source lines 4 a, 4 b and these lines are live (energized). However, because the terminals 18 are not electrically connected to the source cables 4 a, 4 the device is still safe to work on/around.

FIG. 15 illustrates another front view of an the OCPD 11 illustrated in FIG. 14, showing a configuration of the OCPD 11 where the fuse cases 22 and corresponding fuses 8 are almost inserted, but the fuses 8 are not tightened. At this point terminals 8 are still not energized.

FIG. 16 illustrates another front view of the OCPD 11 illustrated in FIG. 15, illustrating the screw-in fuse cases 22 are fully inserted and the fuses 8 are tightened. In this arrangement, terminals 8 are now electrically connected to the source lines 4 a, 4 b and will be energized if the source lines are energized.

FIG. 17 illustrates another example of OCPD 11 that includes a fuse block embodiment with a four bolt 15 clamp-style tap connection (for example, which may be similar to the clamp implementation illustrated in FIG. 10). The illustrated OCPD 11 includes fuses disposed between terminals 18 for connection to an alternative energy source and the source lines 4 a, 4 b. In addition, this arrangement illustrates a twin alternative energy breaker 23 connected in front of the man circuit breaker 3. The twin breaker 23 uses only a single breaker space (for example, one inch wide) for a two-pole breaker. Certain aspects of this implementation of the OCPD 11 are further illustrated in FIG. 18.

FIG. 18 illustrates an example of an implementation of the OCPD 11 illustrated in FIG. 17 and provides further details of the implementation. The OCPD 11 includes fuse casings 22 such that power from the alternative power source passes through the fuses to the source lines 4 a, 4 b. This arrangement of the OCBD 11 includes a source coupling portion 11 a and a twin alternative energy breaker 23 connected in front of the man circuit breaker 3. The breaker 23 can be used to connect an alternative energy source to the source coupling portion 11 a, for example, in areas that may require alternative energy sources to be connected to the source lines 4 a, 4 b via a circuit breaker.

FIGS. 19 and 20 illustrate an example of an OCPD 11 connected to source lines 4 a, 4 b that provide power into a circuit breaker panel 2, and which certain aspects of various embodiments are also further illustrated in FIG. 18. This configuration of the OCPD 11 does not use fuses, instead having a circuit breaker 23 connected between an alternative energy source and source lines 4 a, 4 b. The OCPD 11 includes source line receptacles 62 where the source lines 4 a, 4 b are seated when coupled to the OCPD 11. The circuit breaker 23 is a twin two-pole circuit breaker that is dimensioned to use the space of a normal sized breaker space for a two-pole circuit breaker. As illustrated in FIG. 20, this OCPD 11 implementation includes clamping-type coupler structure similar to that as described in reference to FIG. 11. For example, two sets of tapping spikes 12, lower clamping structure 129 and upper clamping structure 130, and a screw 15 disposed through an upper surface 63 of the OCPD 11 through the upper clamping portion 130 and is coupled to the lower clamping portion. The lower clamping portion 129 can be moved towards the upper clamping structure 130 by turning screw 15, which drives the two sets of tapping spikes 12 into the source lines 4 a, 4 b that are seated in the source line receptacles.

FIG. 21 illustrates an example of an implementation of an OCPD 11 that is used to couple an alternative energy source to source lines 4 a, 4 b. The OCPD 11 is configured to be installed without de-energizing the source lines 4 a, 4 b and without disconnecting the source lines from the main breaker 3. The OCPD 11 is electrically coupled to the source lines 4 a, 4 b at a point before the source lines are coupled to the main circuit breaker 3 such that power that flows between the alternative energy source through the OCPD 11 and the source lines 4 a, 4 b does not go through the busbars 5 a, 5 b. For example, as illustrated in FIG. 21, the OCPD 11 is disposed on and electrically coupled to the source lines 4 a, 4 b before the source lines 4 a, 4 b from the electric meter 1 reach the main breaker 3. The OCPD 11 illustrated in FIG. 21 is also sized to fit within a circuit breaker panel 2. The OCPD 11 can include various means to electrically couple to the source lines 4 a, 4 b, and to an alternative energy source. Implementation of the OCPD 11 in FIG. 21 includes a twin two-pole circuit breaker 23 that is dimensioned to use the space of a normal sized breaker space of a typical two-pole circuit breaker. This implementation of the OCPD 11 is configured to easily push-on to the source line 4 a, 4 b and electrically connect to the source lines 4 a, 4 b using threaded slot connectors and slotted nuts 14, which are further described in reference to FIGS. 30A-30D. Implementations of this OCPD 11 can also be used in a three-phase application.

FIG. 22 illustrates an example of an implementation of an OCPD 11 that is used to couple an alternative energy source to source lines 4 a, 4 b. The OCPD 11 is configured to be installed without de-energizing the source lines 4 a, 4 b and without disconnecting the source lines 4 a, 4 b from the main breaker 3. The OCPD 11 is electrically coupled to the source lines 4 a, 4 b at a point before the source lines are coupled to the main circuit breaker 3 such that power that flows between the alternative energy source through the OCPD 11 and the source lines 4 a, 4 b does not go through the busbars 5 a, 5 b. For example, as illustrated in FIG. 21, the OCPD 11 is disposed on and electrically coupled to the source lines 4 a, 4 b before the source lines from the electric meter 1 reach the main breaker 3. The OCPD 11 illustrated in FIG. 22 is also sized to fit within a circuit breaker panel 2. The OCPD 11 can include various means to electrically couple to the source lines 4 a, 4 b, and to an alternative energy source. The OCPD 11 implementation in FIG. 22 includes a twin two-pole circuit breaker 23 that is dimensioned to use the space of a normal sized breaker space of a typical two-pole circuit breaker. This implementation of the OCPD 11 is configured to easily push-on to the source line 4 a, 4 b and electrically connect to the source lines 4 a, 4 b, having crimp connectors to electrically couple the OCPD 11 to the source lines 4 a, 4 b, which are further described in reference to FIGS. 31A-31D. Implementations of this OCPD 11 can also be used in a three-phase application.

FIGS. 23-39 illustrate various implementations of an alternative energy feed-back device OCPD 11 that includes a power transfer bar 24. Such implementations that may be used in a circuit breaker panel 2 to mitigate overcurrent protection faults when connecting an alternative energy source to source lines 4 a, 4 b by bypassing busbars 5 a, 5 b in the circuit breaker panel 2. FIGS. 23-29B illustrate examples of implementations of OCPD's that are dimensioned to be incorporated in a circuit breaker panel 2. FIGS. 32-39 show additional detail of the various implementations disclosed in FIGS. 23029B, as indicated in the figures and/or the description of the figures.

FIGS. 23-29B illustrate power systems that may be in a residence or a business, that include source lines 4 a, 4 b and a neutral line/bus 32 providing 240VAC to the circuit breaker panel 2. As in many of the other figures in this disclosure, the source lines 4 a, 4 b are illustrated as electrically connecting a utility meter 1 to a main circuit breaker 3 which has two circuit breakers, one breaker for each of the phase A 120VAC and phase B 120VAC as provided by the source lines 4 a, 4 b. The two circuit breakers of main circuit breaker 3 are each connected to one of the busbars 51, 5 b to provide power as needed to the other breakers 40 in the circuit breaker panel 2.

In these implementations, the OCPD 11 is coupled to the source lines 4 a, 4 b using a means for electrical coupling, for example, but not limited to, one of the examples of means for electrical coupling (for example, threaded slot connectors 47 and threaded slot nuts 14, crimp couplers 67 with tapping spikes 12, upper and lower clamping structure 130, 129, screw-down bolt style, etc.). Other means of electrical coupling the OCPD 11 to the source lines 4 a, 4 b may also be used. Examples of the various implementations of means for coupling the OCPD 11 to the source lines 4 a, 4 b are shown in FIGS. 32-39. The means for coupling illustrated in FIGS. 32-39 may be similar, or identical, to other means of coupling described herein.

The power transfer bar 24 includes an electrical bus for providing power passing through the circuit breaker 23 to the source lines 4 a, 4 b, via a coupling means. In typical embodiments the power transfer bar 24 includes two electrical busses to each provide power to one of source lines 4 a and 4 b. The power transfer bar 24 of the alternative energy feed-back device OCPD 11 includes two electrical busses to provide electrical connections between the electrical coupling means that is coupled to the source lines 4 a, 4 b and the terminals 18 for connecting to the alternative energy source. The terminals 18, the power transfer bar 24, and the coupling mechanism to the source lines 4 a, 4 b provide an electrical path to provide power back to the meter 1 and the utility company without passing the current from the alternative power source through one of the busbars 5 a, 5 b. In particular, the electrical path for power from alternative energy source fed back to the meter 1 may be from the alternative energy source to terminals 18, through circuit breaker 23 to the power transfer bar 24, through electrical busses of the power transfer bar 24 to the source line coupler and to the source lines 4 a, 4 b for example through spiking taps 12. Circuit breaker 23 may be disposed on the busbars 5 a, 5 b for stability but the circuit breaker 23 is not directly electrically connected (or electrically clipped) to the busbars 5 a, 5 b such that power from an alternative energy device that is fed back through terminals 18 does not pass through the busbars 5 a, 5 b. In some implementations, circuit breaker 23 is a regular is configured for the electrically connecting to the busbars 5 a, 5 b. In such cases, the power transfer bar 24 may also be configured to block the electrical connections between circuit breaker 23 and busbars 5 a, 5 b. For example, the power transfer bar 24 is configured to extend under or alongside at least a portion of circuit breaker 23, and further configured such that the circuit breaker 23 electrically connects to a portion of the power transfer bar 24 connecting the busses of the power transfer bar 24 to the circuit breaker 23. In such embodiments, the electrical busses of the power transfer bar 24 connect to power input terminals on the breaker 23 (which may be the input terminals that are normally electrically connected to the busbars 5 a, 5 b).

Example of the power transfer bar 24 are illustrated in FIGS. 23-29B. In some implementations, the power transfer bar 24 mechanically extends from the coupling means across the main circuit breaker 3 in a direction generally perpendicular to the direction of the source lines 4 a, 4 b where the source lines 4 a, 4 b connect to the main circuit breaker. In such implementations, the power transfer bar 24 is disposed adjacent to the main circuit breaker 3. As illustrated in FIGS. 23-29B, the power transfer bar 24 may further extend across, and is adjacent to, at least a portion of at least one other single breaker or double breaker 23 that is disposed adjacent to the main circuit breaker 3. In some arrangements of circuit breaker panels, such configurations of the power transfer bar 24 dispose the terminals 18 in an area of the circuit breaker panel where there is room to run wires from the alternative energy source to connect to the terminals 18.

FIG. 23 illustrates an example of an implementation of an OCPD 11 that includes terminals 18 for receiving power from an alternative energy source. The OCPD 11 is configured to be installed without de-energizing the source lines 4 a, 4 b and without disconnecting the source lines from the main breaker 3. The OCPD 11 is electrically coupled to the source lines 4 a, 4 b in a circuit breaker panel at a point before the source lines 4 a, 4 b are coupled to the main circuit breaker 3 such that power that flows between the alternative energy source through the OCPD 11 to the source lines 4 a, 4 b and does not go through the busbars 5 a, 5 b. For example, as illustrated in FIG. 23, the OCPD 11 is disposed over and electrically coupled to the source lines 4 a, 4 b before the source lines 4 a, 4 b from the electric meter 1 reach the main breaker 3. In some implementations, the OCPD 11 is connected to a busbars 5 a, 5 b but only for stability purposes (for example the circuit breaker 23 may be directly physically coupled to busbars 5 a, 5 b but not directly electrically coupled to the busbars 5 a, 5 b) such that the OCPD 11 does not transfer power through the busbars 5 a, 5 b. The OCPD 11 illustrated in FIG. 23 is dimensioned to fit within a circuit breaker panel 2 adjacent to the main circuit breaker 23. The OCPD 11 can include various means to electrically couple to the source lines 4 a, 4 b, and to an alternative energy source.

Additional aspects of the illustrated OCPD 11 are illustrated in FIGS. 32A-32D. The OCPD 11 is configured to push-on to the source line 4 a, 4 b and electrically connect to the source lines 4 a, 4 b using threaded slot connectors 47 and slotted nuts 14. The OCPD 11 also includes terminals 18 for connecting to an alternative energy source and a power transfer bar 24 that includes electrical busses for electrically connecting the source lines 4 a, 4 b to the dual two-pole alternative energy circuit breaker 40 b. OCPD 11 also includes terminals 18 that are electrically connected to the dual two-pole alternative energy circuit breaker 40 b and provide a connection point for the alternative energy source.

FIG. 24 is a similar implementation of an OCPD 11 as illustrated in FIG. 23, except that the circuit breaker 23 is a twin type two-pole breaker (not a standard dual breaker as illustrated in FIG. 23) disposed to the side of the main breaker 3. The OCPD 11 includes a power transfer bar 24. A twin breaker can be used when there is limited space within the circuit breaker panel 2. Some circuit breaker panels have ample room, in which case one wouldn't need to use a narrower twin breaker, which costs more (the narrower the breaker, the more it costs). No fuses are used in this OCPD 11 implementation.

The circuit breaker 23 may be physically connected to one or more of the busbars 5 a, 5 b for stability purposes but does not transfer power through the busbars 5 a, 5 b. The OCPD 11 of FIG. 24 is configured to be installed without de-energizing the source lines 4 a, 4 b and without disconnecting the source lines 4 a, 4 b from the main breaker 3. The OCPD 11 is electrically coupled to the source lines 4 a, 4 b at a point before the source lines are coupled to the main circuit breaker 3 such that power that flows between the alternative energy source through the OCPD 11 and the source lines 4 a, 4 b does not go through the busbars 5 a, 5 b. For example, as illustrated in FIG. 24, the OCPD 11 is electrically coupled to the source lines 4 a, 4 b before the source lines from the electric meter 1 reach the main breaker 3. The OCPD 11 illustrated in FIG. 24 is also sized to fit within a circuit breaker panel 2. The OCPD 11 can include various means to electrically couple to the source lines 4 a, 4 b, and to an alternative energy source. This implementation of the OCPD 11 is configured to easily push-on to the source line 4 a, 4 b and electrically connect to the source lines 4 a, 4 b using threaded slot connectors and slotted nuts 14, which are further described in reference to FIGS. 33A-33D.

FIG. 25 illustrates an example of an implementation of an OCPD 11 that attaches to the source lines 4 a, 4 b using crimp-style connectors, further illustrated in FIGS. 34A-34D. In other implementations, the OCPD 11 may include various means to electrically couple to the source lines 4 a, 4 b, and to an alternative energy source. The OCPD 11 also includes a power transfer bar 24 that has electrical busses to transfer electrical power between terminals 18 and the source lines 4 a, 4 b, and utilizes fuses in fuse casings 22 disposed between the terminals 18 and the source lines 4 a, 4 b. Although this implantation includes fuses 22, this implementation also routes power from the terminals 18 through circuit breaker 23 to the power transfer bar 24, as described in reference to FIG. 23. In this implementation, standard double circuit breaker 23 is connected to the busbars 5 a, 5 b for stability but not as a direct electrical connection to the busbars 5 a, 5 b. The OCPD 11 is configured to be installed without de-energizing the source lines 4 a, 4 b and without disconnecting the source lines 4 a, 4 b from the main breaker 3. The OCPD 11 is electrically coupled to the source lines 4 a, 4 b at a point before the source lines are coupled to the main circuit breaker 3 such that power that flows between the alternative energy source through the OCPD 11 and the source lines 4 a, 4 b does not go through the busbars 5 a, 5 b. For example, as illustrated in FIG. 25, the OCPD 11 is disposed on and electrically coupled to the source lines 4 a, 4 b before the source lines 4 a, 4 b from the electric meter 1 reach the main breaker 3. The OCPD 11 illustrated in FIG. 25 is also sized to fit within a circuit breaker panel 2.

FIG. 26 illustrates an example of an implementation of an OCPD 11 that attaches to the source lines 4 a, 4 b using crimp-style connectors, further illustrated in FIGS. 35A-35D. In other implementations, the OCPD 11 may include various means to electrically couple to the source lines 4 a, 4 b, and to an alternative energy source. The illustrated OCPD 11 is similar to the implementation illustrated in FIG. 25, except that it includes an alternative energy twin circuit breaker 23. The OCPD 11 also includes a power transfer bar 24 that has electrical busses to transfer electrical power between terminals 18 and the source lines 4 a, 4 b, and utilizes fuses in fuse casings 22 disposed between the terminals 18 and the source lines 4 a, 4 b. Although this implantation includes fuses 22, this implementation is configured to route power from the terminals 18 through circuit breaker 23 to the power transfer bar 24. In this implementation, a twin circuit breaker 23 may be connected to the busbars 5 a, 5 b for stability but does not have a direct electrical connection to the busbars 5 a, 5 b. The OCPD 11 is configured to be installed without de-energizing the source lines 4 a, 4 b and without disconnecting the source lines 4 a, 4 b from the main breaker 3. The OCPD 11 is electrically coupled to the source lines 4 a, 4 b at a point before the source lines are coupled to the main circuit breaker 3 such that power that flows between the alternative energy source through the OCPD 11 and the source lines 4 a, 4 b does not go through the busbars 5 a, 5 b. For example, as illustrated in FIG. 26, the OCPD 11 is disposed on and electrically coupled to the source lines 4 a, 4 b before the source lines 4 a, 4 b from the electric meter 1 reach the main breaker 3. The OCPD 11 illustrated in FIG. 26 is also sized to fit within a circuit breaker panel 2.

FIG. 27 illustrates an example of an implementation of an OCPD 11 that includes terminals for receiving power input from alternative energy sources on an another circuit breaker which, in some implementations, is disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 36A-36D. This is a live-load tapered-thread nut tap with fuse block and twin alternative energy breaker (OCPD 11).

FIG. 28 illustrates an example of an implementation of an OCPD 11 that includes terminals 18 for receiving power input from an alternative energy sources, and another circuit breaker 23 (for example, a standard double alternative energy breaker OCPD 11), which is disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 37A-37D. This embodiment is similar to the embodiment illustrated in FIG. 27 and FIGS. 36A-36D, except that circuit breaker 23in FIG. 28 is a standard double alternative energy breaker OCPD 11.

FIG. 29A illustrates an example of an implementation of an OCPD 11 that includes terminals for receiving power input from alternative energy sources on a standard two-pole circuit breaker which, in some implementations, is disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 39A and 39B. This implementation is a live-load crimp-style tap embodiment with a standard double alternative energy breaker OCPD 11.

FIG. 29B illustrates an example of an implementation of an OCPD 11 that includes terminals for receiving power input from alternative energy sources on a twin two-pole circuit breaker which, in some implementations, is disposed beside the main circuit breaker, aspects of which are further illustrated in FIGS. 39C and 39D. This embodiment is a live-load crimp-style tap embodiment with new twin (duplex, tandem) alternative energy breaker (OCPD 11) that is still 2″ across but that supports four circuits (instead of two as with a standard double breaker).

FIGS. 30A-30D illustrate further details of the implementation illustrated in FIG. 21. In this implementation, the OCPD 11 includes a two-pole twin circuit breaker 23 this is disposed in front of the main breaker 3. That is, adjacent to the main circuit breaker 3 on the side where the source lines 4 a, 4 b come into the main circuit breaker 3. The twin circuit breaker 23 is dimensioned to use the space of a normal sized breaker, for example the space of a typical two-pole circuit breaker. FIG. 30A illustrates a top view of the OCPD 11, including twin circuit breaker 23, coupling means threaded slot connectors 47 and slot nuts 14 (shown in FIG. 30A as being wound in against the circuit breaker 23). This is a similar implementation as illustrated in FIG. 8, except that the implementation in FIGS. 30A-30D uses the twin circuit breaker 23 instead of fuses. FIG. 30B illustrates a front view of the OCPB 11 illustrated in FIG. 30A, and illustrates slots 127 which receive the source lines 4 a, 4 b. The OCPD 11 also includes terminals 18 on the lower portion of the OCPD 11 (the lower portion being disposed within the circuit breaker panel) to connect to the alternative energy source. Although not explicitly shown, the one of skill in the art will appreciate that each of the breakers of the twin circuit breaker 23 are connected to one of the source lines 4 a, 4 b via the coupling means, such that the twin circuit breaker is electrically connected between the terminals 18 and the source lines 4 a, 4 b. For example, each of the tapping spikes 12 are electrically coupled to one of the source lines 4 a, 4 b and then connected to one of the breakers of the twin breaker 23, and then each of the twin breakers 23 are connected to one of the terminals 18. FIG. 30C and FIG. 30D illustrate side views of the OCPD 11, where FIG. 30C shows a configuration before tapping spikes 12 are pushed into the source lines 4 a, 4 b and FIG. 30D shows the configuration when the tapping spikes are in electrical contact with the source lines 4 a, 4 b.

FIGS. 31A-31D illustrate further details of the implementation illustrated in FIG. 22. In this implementation, the OCPD 11 includes a two-pole twin circuit breaker 23 this is disposed in front of the main breaker 3. That is, adjacent to the main circuit breaker 3 on the side where the source lines 4 a, 4 b come into the main circuit breaker 3. The twin circuit breaker 23 is dimensioned to use the space of a normal sized breaker, for example the space of a typical two-pole circuit breaker. FIG. 31A illustrates a top view of the OCPD 11 which includes means for connecting terminals 18 of the OCPD 11 to the source lines 4 a, 4 b, which includes twin circuit breaker 23 and deformable spike taps 12 (coupling means) which can be crimped onto the source lines 4 a, 4 b using a crimping tool, for example as illustrated in FIG. 31D. Certain aspects of this OCPD 11 are similar to those illustrated in FIG. 9, except that the implementation in FIGS. 30A-30D uses the twin circuit breaker 23 instead of fuses. FIG. 30B illustrates a front view of the OCPB 11 illustrated in FIG. 30A, and illustrates how the deformable spike taps 12 receive and at least partially surround the source lines 4 a, 4 b, and they are formed to allow the OCPD 11 to be pushed down onto the source lines 4 a, 4 b. OCPD 11 also includes terminals 18 on the upper portion of the OCPD 11 to connect to the alternative energy source. The upper portion may be disposed to be visible in the circuit breaker panel 2. Although not explicitly shown, the one of skill in the art will appreciate that each of the breakers of the twin circuit breaker 23 are connected to one of the source lines 4 a, 4 b via the tapping spikes 12, such that the twin circuit breaker is electrically connected between the terminals 18 and the source lines 4 a, 4 b. For example, each of the tapping spikes 12 are electrically coupled to one of the source lines 4 a, 4 b and then connected to one of the breakers of the twin breaker 23, and then each of the twin breakers 23 are connected to one of the terminals 18. FIG. 30C and FIG. 30D illustrates a side view of the OCPD 11 as described, showing terminals 18 located on an upper portion of the OCPD 11 adjacent to the twin circuit breaker 23.

FIGS. 32A-32D illustrate additional aspects of the OCPD 11 of FIG. 23. FIG. 32A is a top view of a OCPD 11 coupled to the source lines 4 a, 4 b using threaded slot connectors 47 and slotted nuts 14, and FIG. 32B is a front view. The terminals 18 are electrically connected to the circuit breaker 23 so that power received from an alternative energy source pass through the circuit breaker 23, through the power transfer bar 24 and to the source lines 4 a, 4 b via the tapping spikes 12. Accordingly, the power transfer bar 24 is configured to be electrically connected to the circuit breaker 23, for example, at the electrical connection that would normally be connected to one of the busbars 5 a, 5 b, or another electrical connection. In configurations where the power transfer bar 24 connects to the electrical connections of the circuit breaker 23 that normally connect to a busbar, the power transfer bar 24 extends under the circuit breaker 23 to such electrical connections. FIG. 32C illustrates a side view before the OCPD 11 is tapped into the source line 4 a. FIG. 32D illustrates a side view of the OCPD 11 after tap with the tapping spikes 12 electrically connected to the source line 4 a.

FIGS. 33A-33D illustrate additional aspects of the OCPD 11 of FIG. 24, which are similar to those illustrated in FIGS. 32A-32D except that circuit breaker 33A is a twin-type circuit breaker.

FIGS. 34A-34D illustrate additional aspects of the OCPD 11 of FIG. 25, where FIG. 34A is a top view, FIG. 34B is a front view, FIG. 34C is a side view and FIG. 34D illustrates a crimping tool that can be used to crimp the crimp couplers 67 onto source lines 4 a, 4 b that are held in source line receptacles 62. As illustrated in FIG. 34B the power transfer bar 24 of OCPD 11 includes electrical bus 28 a that, as illustrated, is connected to source line 4 a and electrical bus 28 b that is connected to source line 4 b. The electrical busses 28 a, 28 b may extend under a portion of circuit breaker 23 and connect to electrical connectors of circuit breaker 23, making an electrical connection between terminals 18 and electrical busses 28 a, 28 b through the circuit breaker 23.

FIGS. 35A-35D illustrate additional aspects of the OCPD 11 of FIG. 26. where FIG. 35A is a top view, FIG. 35B is a front view, FIG. 35C is a side view and FIG. 35D illustrates a crimping tool that can be used to crimp the crimp couplers 67 onto source lines 4 a, 4 b that are held in source line receptacles 62. As illustrated in FIG. 35B the power transfer bar 24 of OCPD 11 includes electrical bus 28 a that, as illustrated, is connected to source line 4 a and electrical bus 28 b that is connected to source line 4 b. The electrical busses 28 a, 28 b may extend under a portion of twin circuit breaker 23 and connect to electrical connectors of twin circuit breaker 23, making an electrical connection between terminals 18 and electrical busses 28 a, 28 b through the circuit breaker 23.

FIGS. 36A-36D illustrate additional aspects of the OCPD 11 of FIG. 27, where FIG. 36A is a top view of the OCPD 11, FIG. 36B is a front view of OCPD 11, FIG. 36C is a side view of OCBD 11 before it is tapped into source line 4 a, and FIG. 36D is a side view of the OCBD 11 after tapping spikes 12 are tapped into source line 4 a. This implementation includes fuses 22 (for example, for extra protection of electrical devices) such that power fed-back from an alternative energy force passes through terminals 18, the circuit 23, the power transfer bar 24, fuses 22, the coupling means (that in this implementation include threaded slot connectors 47, and slotted nuts 14, and tapping spikes 12) to source lines 4 a, 4 b. Accordingly, the power transfer bar 24 maybe configured similarly to other described configurations of the power transfer bar 24, or another suitable configuration to bus (or transfer) power from the circuit breaker 23 to the coupling means.

FIGS. 37A-37D illustrate additional aspects of the OCPD of FIG. 28. This embodiment is similar to the embodiment illustrated in FIG. 27 and FIGS. 36A-36D, except that circuit breaker 23 in FIG. 28 and in FIGS. 37A-37D is a standard double alternative energy breaker OCPD 11.

FIG. 38 further illustrates aspects of some components of an OCPD 11 that include using a threaded slot connector 47 and a slotted nut 14, for example, as illustrated in FIGS. 8, 21, 23, 24, 27, 28, 30, 33 and other similar embodiments. The threaded slot connector 47 may have a tapered thread structure (as illustrated in FIG. 38) such that the threaded slot connector has a wide portion 47 a (in diameter) and a narrow portion 47 b (in diameter). For this type of coupling embodiment, slotted nut 14 may include a tapered thread structure 14 a, 14 b that is wider at the portion 14 a of slotted nut 14 that first contacts the threaded slot connector 47 narrow portion 47 b when wound on, and narrower at the portion 14 b that later contacts the threaded slot connector 47 narrow portion 47 b. FIG. 38 also illustrates tapping spike 12 connected to bus 60, which is connected to transfer bar 59. Transfer bar 59 may be incorporated as a bus in an the power transfer bar 24 described elsewhere herein.

FIGS. 39A and 39B illustrate examples of embodiments that use a crimping coupler to electrically couple an OCPD 11 (illustrated in FIG. 29A) to source lines 4 a, 4 b. The OCPD 11 includes crimpable coupling means that are deformable, when crimped by a crimp tool, and also includes tapping spikes 12. The OCPD 11 also includes a power transfer bar 24 that includes two electrical busses 28 a, 28 b, and is configured to bus power from the circuit breaker 23 to the coupling means. The circuit breaker 23 in this implementation is a standard two-pole circuit breaker. As in the other embodiments, coupling the OCPD 11 to the source lines 4 a, 4 b can be done while the source lines are live, obviating the need to remove the utility meter.

FIGS. 39C and 39D illustrate examples of embodiments that use a crimping coupler to electrically couple an OCPD 11 (illustrated in FIG. 29B) to source lines 4 a, 4 b. The OCPD 11 includes crimpable coupling means that are deformable, when crimped by a crimp tool, and also includes tapping spikes 12. The OCPD 11 also includes a power transfer bar 24 that includes two electrical busses 28 a, 28 b, and is configured to bus power from the circuit breaker 23 to the coupling means. The circuit breaker 23 in this implementation is a twin circuit breaker. As in the other embodiments, coupling the OCPD 11 to the source lines 4 a, 4 b can be done while the source lines are live, obviating the need to remove the utility meter.

FIG. 40 is a schematic illustration of a main service panel with an installed bypass breaker in electrical communication with power transfer posts on the source lines before the main breaker. Power transfer posts 33 are located along source lines 4 a and 4 b before the main breaker 3. The power transfer posts 33 tap into source lines 4 a and 4 b to provide an electrical connection to the busbar bypass breaker 11 while bypassing the main breaker 3.

FIG. 41A is a detail cross-sectional view of the power transfer post within region A of FIG. 40. Electrical lugs 31 and clamping screws 32 provide a connection between the source line 4 a and bypass power line 40 a. The illustrated embodiment utilizes an electrical lug 31 and clamping screw 42 on each of the source line 4 a and bypass power line 40 a to tap into the source line 4 a. However, any combination of other appropriate connecting or tapping structures, including but not limited to structures and devices discussed elsewhere in the present application, can be used in place of or in conjunction with an electrical lug and/or clamping screw to tap into the source line 4 a and provide an electrical connection between the bypass power line 40 a and the source line 4 a.

FIG. 41B is a detail cross-sectional view of the region A of FIG. 40, along a plane orthogonal to the plane of FIG. 41A at the power transfer post. It can be seen in FIG. 41B that a bimetallic strip 30 extends between the electrical lug 31 in contact with the bypass power line 40 a and the electrical lug (see FIG. 41A) in contact with the source line 4 a.

A bimetallic strip can be used to convert a temperature change into a mechanical displacement. The bimetallic strip is a structure in which the amount and/or direction of curvature is dependent upon the temperature of the device. The bimetallic strip 30 includes at least first and second metallic strips which are secured relative to one another. The first metallic strip includes a first material having a first coefficient of thermal expansion and the second metallic strip includes a second material having a second coefficient of thermal expansion which is greater than the first coefficient of thermal expansion of the first material. The first and second metallic strips may be secured relative to one another at multiple points along their length, by means such as brazing, welding, or rivets. Any other suitable securing means may also be used. In some embodiments, the first material may include steel and the second material may include copper or brass. However, any suitable pair of materials may be used.

Depending on the particular design of the bimetallic strip 30, the range of curvature over a range of temperatures may or may not include a temperature at which the curvature of the bimetallic strip is essentially zero. In some embodiments, a section of the bimetallic strip 30 may be configured to transition through a substantially planar state when the bimetallic strip 30 is at a specific temperature. In other embodiments, at least a portion of the bimetallic strip 30 may be configured to remain in a concave shape until a threshold temperature is reached, at which point the strain induced by differential expansion of the first and second metal layers causes the concave portion of the bimetallic strip to snap to a convex shape, reversing the direction of curvature of that portion of the bimetallic strip. In other embodiments, the bimetallic strip 30 may be in the form of a coil, rather than a semi-linear strip, and changes in temperature will tighten or relax the coil. The use of a coiled bimetallic strip can increase the sensitivity of the bimetallic strip structure to temperature changes.

As the temperature of the bimetallic strip 30 increases, the second metallic strip will expand at a rate greater than the first metallic strip. Thus, in some embodiments, the bimetallic strip 30 at higher temperatures will be curved such that the second metallic strip, which has the higher coefficient of thermal expansion, is on the outer side of the curve or coil. In other embodiments, where the bimetallic strip 30 is curved such that the second metallic strip is on the interior side of the curve or coil, increasing the temperature can reduce the curvature or while the second metallic strip remains on the interior side of the curve or coil.

In the illustrated embodiment, the bimetallic strip 30 can be configured such that the central portion of the bimetallic strip 30 bulges towards the lugs 31 at safe operating temperatures, holding the contacts 34 at the ends of the bimetallic strip 30 in contact with the facing contacts 34 on the electrical lugs 31 (see FIG. 42). When the bimetallic strip 30 exceeds a threshold temperature, the curvature of the central portion of the bimetallic strip 30 changes so that it bulges away from lugs 31 as seen in FIG. 41B, pulling the contacts 34 at the ends of the bimetallic strip 30 away from the facing contacts 34 on the electrical lugs 31.

FIG. 42 shows the bimetallic strip 30 of the power transfer post of FIG. 41B, with the bimetallic strip shown in an untripped, or reset, position. The reset button 35 can be pushed to displace the central portion of the bimetallic strip 30 reset the curvature of the bimetallic strip 30 to a position where the central portion bulges towards the electrical lugs as shown. So long as the temperatures of the source line 4 a and the bypass power line 40 a are below the threshold temperature, the bimetallic strip 30 will remain in the untripped position. If the temperature of the source line 4 a and the bypass power line 40 a is above the threshold temperature, the bimetallic strip 30 will quickly trip again.

Because the bimetallic strip 30 is a thermally conductive structure in contact with the source line 4 a and the bypass power line 40 a, the temperature of the bimetallic strip 30 will quickly reach and remain at a temperature close to that of the source line 4 a and the bypass power line 40 a. Thus, the bimetallic strip 30 can provide an almost immediate response to elevated temperatures, which represent a significant fire hazard. This response can be faster than the response of circuit breakers which trigger based on excessive amperage across the breaker, as such circuit breakers can experience a delay before triggering. The use of bimetallic strips 30 as described herein can provide a supplemental safety precaution against fire risk from elevated temperatures. In the particular embodiment illustrated in FIG. 40 and associated figures, in which a bypass breaker is installed, tripping the bimetallic strip 30 in a power transfer post can decouple the bypass power line 40 a from the source line 4 a if a temperature threshold is reached.

In the illustrated embodiment, the bimetallic strip 30 forms a part of the circuit connecting the source line 4 a to the bypass power line 40 a. Flexure of the bimetallic strip 30 sufficient to separate at least one of the contacts 34 of the bimetallic strip 30 from the facing contact 34 of an electrical lug 31 will interrupt the circuit, and disconnect the source line 4 a to the bypass power line 40 a. In other embodiments, however, a bimetallic strip 30 in contact with at least one of the source line 4 a and the bypass power line 40 a can be used to directly or indirectly cause displacement of a separate conductive structure connecting the source line 4 a and the bypass power line 40 a, interrupting that connection. Thus, a bimetallic strip can be used to interrupt the connection between the source line 4 a and the bypass power line 40 a even without the bimetallic strip forming a part of the electrical circuit connecting the source line 4 a and the bypass power line 40 a.

A similar bimetallic strip safety feature can be included in the power transfer post connecting source line 4 b to the bypass power line 40 b. The bimetallic strips at each power transfer post can be arranged in series with one another, so that tripping of one of the bimetallic strips results in tripping of the other bimetallic strip, even if only one of the power transfer posts is experiencing overheating. One possible structure for triggering the tripping of the other bimetallic strip is discussed with respect to FIGS. 45A and 45B, although any other suitable structure may also be used.

In addition to the use of bimetallic strips at the power transfer posts, bimetallic strips can also be used as safety features within the bypass breakers to monitor the temperature of the busbars. FIG. 43 schematically illustrates connections to alternating busbars in a series of breakers in a main service panel such as the service panel of FIG. 40. Each breaker, such as bypass breaker 11, is in contact with both busbar 5 a and busbar 5 b. Thus, including two bimetallic strip safety features in a given breaker permits the monitoring of the temperatures of both busbars 5 a and 5 b.

FIG. 44A is a partial cutaway side view of region C of FIG. 43 which schematically illustrates a connection between a busbar and a bypass breaker which utilizes a bimetallic strip. FIG. 44B is a more detailed view of the partial cutaway side view of FIG. 44A, illustrating the bimetallic strip connection to the circuit breaker. The circuit breaker 11 includes a spring clamp 37, which may in some embodiments be a steel spring clamp, which retains a portion of busbar 5 b, such as a tab which extends in the direction of the circuit breaker 11. The spring clamp 37 forms part of the electrical connection which transfers load from the busbar 5 b to the circuit breaker 11. A bimetallic strip 30, similar to the bimetallic strip 30 described with respect to FIGS. 41A and 42, forms a connection between the spring clamp 37 and a breaker component 137. The bimetallic strip 30 is illustrated in a tripped position, in which the curvature of the central portion of the bimetallic strip 30 separates contacts 34 on the bimetallic strip 30 from contacts 34 on the spring clamp 37 and breaker component 137.

FIG. 45A is a side cross-sectional view of another embodiment of a bypass breaker with two bimetallic strips arranged in series, shown in a tripped position. The bypass breaker 11 includes a first spring clamp 57 a which engages a tab of busbar 5 a, and a second spring clamp 57 b which engages a tab of busbar 5 b. A contact 54 a on first spring clamp 57 a is separated from a facing contact 57 c of bimetallic strip 50 a, as the bimetallic strip 50 a is in a tripped position in which the central portion of the bimetallic strip 50 a bulges away from first spring clamp 57 a. The tripped positioning of the bimetallic strip 50 a also results in a separation between bimetallic strip contact 54 e, and a contact 54 g on breaker component 157 a. In the illustrated embodiment, the tripped positioning of the bimetallic strip 50 a breaks the circuit connecting the busbar 5 a to the breaker component 157 a.

The bypass breaker 11 also includes a second bimetallic strip 50 b, which is also in a tripped position. A contact 54 b on second spring clamp 57 b is separated from a facing contact 57 d of bimetallic strip 50 b, due to the tripped positioning of the bimetallic strip 50 b in which the central portion of the bimetallic strip 50 b bulges away from second spring clamp 57 b. The tripped positioning of the bimetallic strip 50 b also results in a separation between bimetallic strip contact 54 f, and a contact 54 h on breaker component 157 b.

A linking member 74 extends between bimetallic strip 50 a and 50 b. A channel 72 or other guide permits longitudinal translation of linking member 74 along the axis of the channel 72, while otherwise constraining translation of the linking member 74. The linking member includes a first notch 175 a retaining bimetallic strip 50 a, and a second notch 175 b retaining bimetallic strip 50 b. The width of notches 175 a and 175 b is less than the range of movement of the retained portions of bimetallic strips 50 a and 50 b between their tripped and untripped positions, such that movement of, for example, bimetallic strip 50 a between an untripped and a tripped position results in longitudinal translation of the linking member 74 through the channel 72, and pulls the other bimetallic strip 50 b to a tripped position as well, regardless of the temperature of the bimetallic strip 50 b. This series arrangement of the bimetallic strips 50 a and 50 b ensures that both bimetallic strips 50 a and 50 b are tripped if the temperature of one of the strips 50 a or 50 b exceeds a threshold temperature.

FIG. 45B is a side cross-sectional view of the bypass breaker of FIG. 45B, with the bimetallic strips shown in a reset position. The breaker 11 also includes a reset button 71, and a reset arm 75 extending into the interior of the breaker 11. Translation of the reset button 71 and reset arm 75 can be constrained by retaining members 73 arranged along the length of the reset arm 75, such as pins, rings, or other structures which permit, for example, axial translation while constraining transverse translation.

The linking member 74 includes a cam surface 174 oriented at a first angle, and the reset arm 75 includes a facing cam surface 173 oriented at a second angle complementary to the first angle of the cam surface 174. When the reset button is pressed downward, axial translation of the reset bar causes the facing cam surface 173 of the reset arm 75 to engage with the cam surface 174 of the linking member 74, causing axial translation of the linking member 74 towards the spring clamps 57 a and 57 b. The axial translation of the linking member 74 causes the edges of notches 175 a and 175 b to push the bimetallic strips 50 a and 50 b into a reset, or untripped, position as shown in FIG. 45B.

When the bimetallic strip 50 a is pushed back to the untripped position, the contact 54 a on first spring clamp 57 a is brought back into contact with the a facing contact 57 c of bimetallic strip 50 a, and the bimetallic strip contact 54 e is brought back into contact with contact 54 g on breaker component 157 a, completing the connection between the first spring clamp 57 a and breaker component 157 a. Similarly, when bimetallic strip 50 b is pushed back to the untripped position, the contact 54 b on first spring clamp 57 b is brought back into contact with the a facing contact 57 d of bimetallic strip 50 b, and the bimetallic strip contact 54 f is brought back into contact with contact 54 h on breaker component 157 b, completing the connection between the first spring clamp 57 b and breaker component 157 b.

The steep angle of the cam surfaces allows for substantial travel of the reset button 71 to result in a smaller amount of travel of the linking member 74. This larger travel range of the reset button 71 can provide a clearer visual indication of the status of the bimetallic strips 50 a and 50 b in breaker 11, without requiring a similarly large travel range for the bimetallic strips 50 a and 50 b between their tripped and untripped statuses. In other embodiments, however, other angles can be used, or the reset button may be aligned with the linkage bar, such that cam surfaces to alter the direction of movement are not needed.

The use of bimetallic strips 50 a and 50 b as safety features in the bypass breaker 11 provides a rapid way to disconnect the bypass breaker 11 and associated alternative energy or other source from the busbars 5 a and 5 b if the busbars 5 a and 5 b begin to overheat, presenting a fire hazard. This provides a level of overcurrent protection which can be used in conjunction with other safety features, such as other features of the circuit breaker 11 or a main breaker, to provide supplemental protection against overheating and fire.

The use of a bimetallic safety strip as a safety feature can be used with or without a bypass system, as any main panel can be at risk of overheating and fire in the time period before a circuit breaker trips. Thus, these bimetallic safety strips can be installed in any breaker, or at other locations in or adjacent to a main panel. As discussed above with respect to the power transfer posts, the bimetallic strips 50 a and 50 b need not form a part of a circuit which transmits load from the busbars to the bypass breakers, but instead may directly or indirectly trigger motion of another component to break a circuit if the bimetallic strip reaches a threshold temperature. Although some examples of bimetallic strips are described and depicted herein as curved strips which snap from a first position to a second position with opposite curvature, other designs may also be used. These alternative designs include coils, as well as structures and designs which undergo more gradual transitions when a temperature threshold is reached.

FIG. 46 is a cross-sectional view of an alternative energy breaker which utilizes a bimetallic strip safety feature. The breaker includes a power input 18 for power input from an alternative energy source, rather than from main power source. The breaker includes current monitoring probes 26 in electrical communication with a sensor relay 80 which can be configured to sense the total amp load to determine whether the load exceeds the rating of a busbar. If the total amp load exceeds the busbar rating, the alternative energy breaker can be shut off. Wires 79 are in electrical communication and controlled by the sensor relays. Lugs 78 connect sensor wires to the main power. Contacts 54 can be separated to interrupt the electrical connection of the alternative energy breaker.

The alternative energy breaker also includes a bimetallic strip 50 which may be configured as an alternative trigger to the alternative energy breaker, in case the components begin to overheat even when the sensor relay 80 is not triggered. Breaker spring 76 can be used to keep pressure in releasing the bimetallic strip 50. Wire 77 is used to transfer power from the bimetallic strip 50 to the contact arm of the breaker, which supports a contact 54. Curvature induced in the bimetallic strip 50 when a threshold temperature is exceeded will trigger the alternative energy breaker, breaking the circuit and cutting off the alternative power input 18 from the main power busbars.

FIG. 47 illustrates a method (process 470) of inserting a back feed device into a circuit breaker panel where the source lines need not be disconnected and power need not be de-energized for the installation to take place. In this method, the back feed device (for example, an over current protection device) is installed to back feed energy from an energy source to source lines in a preexisting circuit breaker panel. At block 475, the process includes inserting a back feed device in a circuit breaker panel between a main circuit breaker and a utility meter, the back feed device dimensioned to couple to a first source line and a second source line and be disposed within the circuit breaker panel. The back feed device includes a source line coupler configured to couple to the first source line and the second source line and at least partially around the first and second source lines, the source line coupler including a first source line receptacle for receiving the first source line such that the first source line is disposed in the first line receptacle, the first source line receptacle including at least one first conductive tapping spike disposed to contact the first source line when the first source line is secured in the first source line receptacle, and a second source line receptacle for receiving the second source line, the second source line receptacle including at least one second conductive tapping spike disposed to contact the second source line when the second source line is secured in the second source line receptacle. The back feed device further includes terminals for connecting to an alternative power source, the terminals including at least a first terminal and a second terminal, and a first over-current protector and a second over-current protector that stop current from flowing at a predetermined threshold level, the first over-current protector electrically connected between the at least one first tapping spike and the first terminal, and the second over-current protector electrically coupled between the at least one second tapping spike and the second terminal. At block 480 the process 470 couples the source line coupler to the first source line and the second source line, completing the circuit from the terminals to the source lines and to allow an alternative energy source connected to the terminals to back feed power to the first and second source lines. A similar method and back feed device may be used in a three phase application, in other embodiments.

Implementing Systems and Terminology

Implementations disclosed herein provide systems, methods and apparatus for local intensity equalization in region matching techniques. One skilled in the art will recognize that these embodiments may be implemented in hardware, software, firmware, or any combination thereof.

In some embodiments, the circuits, processes, and systems discussed above may be utilized in a wireless communication device. The wireless communication device may be a kind of electronic device used to wirelessly communicate with other electronic devices. Examples of wireless communication devices include cellular telephones, smart phones, Personal Digital Assistants (PDAs), e-readers, gaming systems, music players, netbooks, wireless modems, laptop computers, tablet devices, etc.

The wireless communication device may include one or more image sensors, one or more image signal processors, and a memory including instructions or modules for carrying out the local intensity equalization techniques discussed above. The device may also have data, a processor loading instructions and/or data from memory, one or more communication interfaces, one or more input devices, one or more output devices such as a display device and a power source/interface. The wireless communication device may additionally include a transmitter and a receiver. The transmitter and receiver may be jointly referred to as a transceiver. The transceiver may be coupled to one or more antennas for transmitting and/or receiving wireless signals.

Certain aspects of the over current protection devices maybe monitored by a wireless device to provide information relating to the operation of power being transferred from an alternative energy source to one or more of the source lines 4 a, 4 b. A wireless communication device may wirelessly connect to another electronic device (e.g., base station). A wireless communication device may alternatively be referred to as a mobile device, a mobile station, a subscriber station, a user equipment (UE), a remote station, an access terminal, a mobile terminal, a terminal, a user terminal, a subscriber unit, etc. Examples of wireless communication devices include laptop or desktop computers, cellular phones, smart phones, wireless modems, e-readers, tablet devices, gaming systems, etc. Wireless communication devices may operate in accordance with one or more industry standards such as the 3rd Generation Partnership Project (3GPP). Thus, the general term “wireless communication device” may include wireless communication devices described with varying nomenclatures according to industry standards (e.g., access terminal, user equipment (UE), remote terminal, etc.).

The functions described herein may be stored as one or more instructions on a processor-readable or computer-readable medium. The term “computer-readable medium” refers to any available medium that can be accessed by a computer or processor. By way of example, and not limitation, such a medium may comprise RAM, ROM, EEPROM, flash memory, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray® disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. It should be noted that a computer-readable medium may be tangible and non-transitory. The term “computer-program product” refers to a computing device or processor in combination with code or instructions (e.g., a “program”) that may be executed, processed or computed by the computing device or processor. As used herein, the term “code” may refer to software, instructions, code or data that is/are executable by a computing device or processor.

Software or instructions may also be transmitted over a transmission medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of transmission medium.

The methods disclosed herein comprise one or more steps or actions for achieving the described method. The method steps and/or actions may be interchanged with one another without departing from the scope of the claims. In other words, unless a specific order of steps or actions is required for proper operation of the method that is being described, the order and/or use of specific steps and/or actions may be modified without departing from the scope of the claims.

It should be noted that the terms “couple,” “coupling,” “coupled” or other variations of the word couple as used herein may indicate either an indirect connection or a direct connection. For example, if a first component is “coupled” to a second component, the first component may be either indirectly connected to the second component or directly connected to the second component. As used herein, the term “plurality” denotes two or more. For example, a plurality of components indicates two or more components.

The term “determining” encompasses a wide variety of actions and, therefore, “determining” can include calculating, computing, processing, deriving, investigating, looking up (e.g., looking up in a table, a database or another data structure), ascertaining and the like. Also, “determining” can include receiving (e.g., receiving information), accessing (e.g., accessing data in a memory) and the like. Also, “determining” can include resolving, selecting, choosing, establishing and the like.

The phrase “based on” does not mean “based only on,” unless expressly specified otherwise. In other words, the phrase “based on” describes both “based only on” and “based at least on.”

In the foregoing description, specific details are given to provide a thorough understanding of the examples. However, it will be understood by one of ordinary skill in the art that the examples may be practiced without these specific details. For example, electrical components/devices may be shown in block diagrams in order not to obscure the examples in unnecessary detail. In other instances, such components, other structures and techniques may be shown in detail to further explain the examples.

Headings are included herein for reference and to aid in locating various sections. These headings are not intended to limit the scope of the concepts described with respect thereto. Such concepts may have applicability throughout the entire specification.

It is also noted that the examples may be described as a process, which is depicted as a flowchart, a flow diagram, a finite state diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel, or concurrently, and the process can be repeated. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a software function, its termination corresponds to a return of the function to the calling function or the main function.

The previous description of the disclosed implementations is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these implementations will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the implementations shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. 

What is claimed is:
 1. A device for electrically coupling two power source lines in a circuit breaker panel to an alternative power source, the source lines connected to a main circuit breaker in the circuit breaker panel and each providing power to the circuit breaker panel, to provide an electrical connection between the alternative power source and the power source lines that does not use busbars of the circuit breaker panel for the electrical connection, the device comprising: means for electrically coupling including a first means for electrically coupling to a first source line configured to carry 120VAC phase A and a second means for electrically coupling to a second source line configured to carry 120VAC phase B power with two electrically distinct connections, the means for electrically coupling configured to be placed at least partially around the first and second source lines without cutting or disconnecting the first and second source lines, the means for electrically coupling configured to couple to the first and second source line at a location adjacent to the main circuit breaker in a circuit breaker panel and before the first and second source lines connect to the main circuit breaker; terminals for connecting to an alternative power source, the terminals including at least a first terminal and a second terminal; and means for protecting for an over-current condition electrically connected between the terminals and the means for electrically coupling.
 2. The device of claim 1, wherein the means for electrically coupling comprises: a threaded slot connector having a slot that allows one of the source lines to pass through the slot and be disposed within the interior of the threaded slot connector, the threaded slot connector having external threads and having at least one tapping spike disposed in the interior of the threaded slot collector; and a slotted nut having a slot that allows one of the source lines to pass through the slot and be disposed within the interior to the slotted nut, the slotted nut fitting onto the exterior threads of the threaded slot connector, the slotted nut and the threaded clot connector collectively configured to move the at last one tapping spike to electrically couple to a source line within the threaded slot connector when the slotted nut is wound onto the threaded slot connector.
 3. The device of claim 2, wherein the threaded slot connector comprises a tapered shape that deforms when the slotted nut is wound onto the exterior threads to push the at least one tapping spike into the source line.
 4. The device of claim 3, wherein the means for protecting for an over-current condition comprises at least one fuse.
 5. The device of claim 3, wherein the means for protecting for an over-current condition comprises at least one circuit breaker that is not directly electrically connected to a busbar of the circuit breaker panel.
 6. The device of claim 1, wherein the means for coupling include two sets of one or more tapping spikes, each set of the one or more tapping spikes for electrically connecting to one of the first and second source lines.
 7. The device of claim 1, wherein the means for electrically coupling comprises two sets of one or more tapping spikes, each set of the one or more tapping spikes arranged to at least partially surround one of the source lines when the means for coupling is placed on the source lines, configured to deform to move the one or more tapping spikes to be electrically coupled to the at least partially surrounded source line when the means for coupling is crimped around the source lines.
 8. The device of claim 7, wherein the means for protecting for an over-current condition comprises at least one fuse or at least one circuit breaker.
 9. The device of claim 1, wherein the means for electrically coupling comprises: a source line receptacle configured to at least partially surround a source line passing through the means for electrically coupling, the source line receptacle including at least one tapping spike, a clamping structure disposed along a lower portion of the source line receptacle to secure a source line in the source line receptacle; and at least one connector coupled to the clamping structure and disposed to be actuated from an upper surface of the device, the connector extending from the upper surface of the device to the clamping structure, the connector and clamping structure collectively configured to move the clamping structure to a closed position to secure a source line into the source line receptacle and electrically coupling the at least one tapping spike to the source line when the clamping structure is moved to the closed position.
 10. The device of claim 1, wherein the first means for electrically coupling comprises: a first source line receptacle configured to at least partially surround the first source line when the device is disposed over the first source line so that the first source line passes through the means for electrically coupling, the first source line receptacle including at least one tapping spike, a first clamping structure disposed along a lower portion of the first source line receptacle to secure a source line in the first source line receptacle; and at least one first connector coupled to the first clamping structure and disposed to be actuated from an upper surface of the device, the at least one first connector extending from the upper surface of the device to the first clamping structure, the at least one first connector and the first clamping structure collectively configured to move the first clamping structure to a closed position to secure the first source line into the first source line receptacle electrically coupling the at least one tapping spike to the first source line when the first clamping structure is moved to the closed position; and the second means for electrically coupling comprises: a second source line receptacle configured to at least partially surround the second source line when the device is disposed over the second source line so that the second source line passes through the means for electrically coupling, the second source line receptacle including at least one tapping spike, a second clamping structure disposed along a lower portion of the second source line receptacle to secure a source line in the second source line receptacle, and at least one second connector coupled to the second clamping structure and disposed to be actuated from an upper surface of the device, the at least one second connector extending from the upper surface of the device to the second clamping structure, the at least one second connector and the second clamping structure collectively configured to move the second clamping structure to a closed position to secure the second source line into the second source line receptacle electrically coupling the at least one tapping spike to the second source line when the second clamping structure is moved to the closed position.
 11. The device of claim 10, wherein the means for protecting for an over-current condition comprises at least one fuse or at least one circuit breaker.
 12. The device of claim 1, further comprising a power transfer bar electrically coupled to the means for electrically coupling and extending generally perpendicular to the first and second source lines to fit adjacent to one of more circuit breakers disposed beside the main circuit breaker, the power transfer bar including a first conductive bus electrically coupled to the first means for electrically coupling and to the first terminal, and a second conductive bus coupled to the second means for electrically coupling and the second terminal.
 13. A device for electrically coupling a first source line carrying 120VAC phase A power and a second source line carrying 120VAC phase B power to an alternative power source to feed power from the alternative power source to the first and second source lines without using busbars of a circuit breaker panel, the first and second source lines providing power to a main circuit breaker in a circuit breaker panel, the device comprising: a source line coupler configured to couple to the first source line and the second source line in a circuit breaker panel at least partially around the first and second source lines without cutting or disconnecting the first and second source lines, the source line coupler including a first source line receptacle for receiving the first source line when the device is placed over the first source line such that the first source line is disposed in the first line receptacle, the first source line receptacle including at least one first conductive tapping spike disposed to contact the first source line when the first source line is secured in the first source line receptacle; a second source line receptacle for receiving the second source line when the device is placed over the second source line such that second source line is disposed in the second line receptacle, the second source line receptacle including at least one second conductive tapping spike disposed to contact the second source line when the second source line is secured in the second source line receptacle; terminals for connecting to an alternative power source, the terminals including at least a first terminal and a second terminal; and a first over-current protector and a second over-current protector that stop current from flowing at a predetermined threshold level, the first over-current protector electrically connected between at least one first tapping spike and the first terminal, and the second over-current protector electrically coupled between the at least one second tapping spike and the second terminal.
 14. The device of claim 13, wherein the first and second over-current protectors are fuses.
 15. The device of claim 13, wherein the first and second over-current protectors are circuit breakers.
 16. The device of claim 14, further comprising a power transfer bar electrically coupled to the source line coupler and extending generally perpendicular to first and second source lines that are secured in the source line coupler, the power transfer bar configured to fit adjacent to one of more circuit breakers disposed beside the main circuit breaker, the power transfer bar including a first conductive bus electrically coupled between the at least one first tapping spike and the first terminal, and a second conductive bus electrically coupled between the at least one second tapping spike and the second terminal.
 17. The device of claim 16, wherein the source line coupler comprises; a first clamping structure disposed along a portion of the first source line receptacle to secure the first source line in the first source line receptacle; and at least one connector coupled to the first clamping structure and disposed to be actuated from an upper surface of the device, the connector extending from the upper surface of the device to the first clamping structure, the connector and first clamping structure collectively configured to move the clamping structure to a closed position to secure the first source line into the first source line receptacle and electrically couple the at least one first tapping spike to the first source line when the first clamping structure is moved to the closed position.
 18. The device of claim 17, wherein the first clamping structure is coupled to two connectors disposed to be actuated from the upper surface of the device, the two connectors extending from the upper surface of the device to the first clamping structure and coupled to the first clamping structure.
 19. The device of claim 18, wherein the first clamping structure is configured to be adjusted using one or more of the two connectors coupled to the first clamping structure to change the size of the first source line receptacle.
 20. A method for installing a device to back feed energy from an energy source to source lines in a preexisting circuit breaker panel, the method comprising: inserting a back feed device in a circuit breaker panel between a main circuit breaker and a utility meter, the back feed device dimensioned to couple to a first source line and a second source line and be disposed within the circuit breaker panel, the back feed device comprising: a source line coupler configured to couple to the first source line and the second source line and at least partially around the first and second source lines, the source line coupler including a first source line receptacle for receiving the first source line such that the first source line is disposed in the first line receptacle, the first source line receptacle including at least one first conductive tapping spike disposed to contact the first source line when the first source line is secured in the first source line receptacle; a second source line receptacle for receiving the second source line, the second source line receptacle including at least one second conductive tapping spike disposed to contact the second source line when the second source line is secured in the second source line receptacle; terminals for connecting to an alternative power source, the terminals including at least a first terminal and a second terminal; and a first over-current protector and a second over-current protector that stop current from flowing at a predetermined threshold level, the first over-current protector electrically connected between the at least one first tapping spike and the first terminal, and the second over-current protector electrically coupled between the at least one second tapping spike and the second terminal; and coupling the source line coupler to the first source line and the second source line. 